Res-440 e

RESISTRON
RES-440
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
• Time control, heatsealing time and cooling time settable
• Preheating
• Configurable relay output, e.g. "end of cycle"
• Time or temperature-controlled cooling phase
• Signal output for "Temperature OK"
• 0…10VDC analog output for ACTUAL temperature
Version 1
• Alarm function with fault diagnosis
Identical design to and compatible with RES-222, -230, -241, -242

27.7.20
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 .................. 4 10 Controller functions . . . . . . . . . . . . . . . . . 34
1.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 4 10.1 Indicators and controls . . . . . . . . . . . 35
1.2 Intended use . . . . . . . . . . . . . . . . . . . . 4 10.2 Display . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Heatsealing band ................ 4 10.3 Navigation in the menus . . . . . . . . . . 37
1.4 Impulse transformer .............. 5 10.4 Menu structure . . . . . . . . . . . . . . . . . . 39
1.5 Current transformer PEX-W4/-W5 . . . . 5 10.5 Two-digit numbering system up to soft-
1.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 5 ware revision 027 . . . . . . . . . . . . . . . 41
1.7 Maintenance . . . . . . . . . . . . . . . . . . . . 5 10.6 Menu steps . . . . . . . . . . . . . . . . . . . . 42
1.8 Transportation . . . . . . . . . . . . . . . . . . . 5 10.7 Temperature setting (set point selection)
50
1.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 6
10.8 Temperature indication/actual value
2 Application . . . . . . . . . . . . . . . . . . . . . . . . . . 8 output . . . . . . . . . . . . . . . . . . . . . . . . . 51
3 Principle of operation . . . . . . . . . . . . . . . . . 8 10.9 Automatic zero calibration (AUTOCAL) .
53
4 Description of the controller ........... 9
10.10 "START" signal (HEAT) . . . . . . . . . . . 54
5 Accessories and modifications . . . . . . . . 10
10.11 "PREHEAT" signal (preheating) . . . . 55
5.1 Accessories . . . . . . . . . . . . . . . . . . . . 10
10.12 Cycle counter . . . . . . . . . . . . . . . . . . . 57
5.2 Modifications (MODs) . . . . . . . . . . . . 11
10.13 Hold mode . . . . . . . . . . . . . . . . . . . . . 57
6 Technical data . . . . . . . . . . . . . . . . . . . . . . 13 10.14 Measuring impulse duration (as of soft-
7 Dimensions/front panel cutout . . . . . . . . . 15 ware revision 026) . . . . . . . . . . . . . . . 58
8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 16 10.15 Automatic phase angle compensation

(AUTOCOMP) (as of software
8.1 Installation procedure . . . . . . . . . . . . 16
revision 100) . . . . . . . . . . . . . . . . . . . 59
8.2 Installation steps . . . . . . . . . . . . . . . . 17
10.16 Locking the "HAND" key (as of software
8.3 Power supply . . . . . . . . . . . . . . . . . . . 18 revision 100) . . . . . . . . . . . . . . . . . . . 60
8.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 19 10.17 Temperature unit Celsius / Fahrenheit (as
8.5 Current transformer PEX-W4/-W5 . . . 19 of software revision 106) . . . . . . . . . . 60
8.6 Wiring diagram (standard) . . . . . . . . . 21 10.18 Disabling the Configuration menu . . . 60
8.7 Wiring diagram with booster 10.19 Setting the display brightness (VF display
connection . . . . . . . . . . . . . . . . . . . . . 22 only) . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9 Startup and operation . . . . . . . . . . . . . . . . 23 10.20 Undervoltage detection . . . . . . . . . . . 61
9.1 Front view of the controller . . . . . . . . 23 10.21 Diagnostic interface/visualization software
(as of software revision 100) . . . . . . . 63
9.2 Rear view of the controller . . . . . . . . . 23
10.22 Booster connection . . . . . . . . . . . . . . 63
9.3 Controller configuration . . . . . . . . . . . 24
10.23 Time control (timer function) . . . . . . . 64
9.4 Heatsealing band . . . . . . . . . . . . . . . 31
10.24 System monitoring/alarm output . . . . 76
9.5 Startup procedure . . . . . . . . . . . . . . . 33
10.25 Error messages . . . . . . . . . . . . . . . . . 77
10.26 Fault areas and causes . . . . . . . . . . . 81
11 Factory settings . . . . . . . . . . . . . . . . . . . . . 83
11.1 Customer settings (as of software
revision 100) . . . . . . . . . . . . . . . . . . . 85
Page 2 RES-440 Version 1

12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 85
13 How to order . . . . . . . . . . . . . . . . . . . . . . . 86
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Version 1 RES-440 Page 3

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.

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 7. 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.

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!

!

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-440 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)

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 and PP films in:
• Vertical and horizontal f/f/s machines
• Pouch, filling and sealing machines
• Film wrapping machines
• Pouch-making machines
• Group packaging machines
• L-sealers
• etc.
The use of RESISTRON® temperature controllers results in:
• Repeatable quality of the heatseals under any conditions
• Increased machine capacity
• Extended life of the heatsealing bands and teflon coatings
• Simple operation and control of the sealing process
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.
The thermoelectric control loop which is formed has a highly dynamic response because purely electrical variables
are measured at a high sampling rate. A high secondary current can be controlled with only minimal power loss
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.
PLEASE NOTE!
RESISTRON® temperature controllers play a significant role in enhancing the performance of modern machines.
However, the full benefit can only be obtained from the advanced technology offered by this control system if all

Description of the controller
the system components, in other words the heatsealing band, the impulse transformer, the wiring, the timing sig-
nals and the controller itself, are compatible with one another.
We will be pleased to
contribute our many
years of experience
towards optimizing your
heatsealing system.
Heatsealing band R = f (T)
RESISTRON controller
IR UR Actual value
Current
transformer R=f(T)
Indicators
U2 Control
and
sec. Start
U1 logic controls
_
prim. or
+ Set point bus interface
Impulse transformer
LINE
4 Description of the controller

The microprocessor technology endows the RESISTRON® temperature controller RES-440 with previously unat-
tainable capabilities:
• Very simple operation thanks to AUTOCAL, the automatic zero calibration function.
• Good dynamic response of the control system thanks to AUTOTUNE, which adapts automatically to the 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 software revision 100) 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 to 63Hz.
• Increased protection against dangerous conditions, such as overheating of the heatsealing band.
A time control (timer) function integrated in the controller enables the complete heatsealing process to be con-
trolled on simple machines, such as table heatsealing tools. A configurable relay output can be used to drive
motors, energize magnets etc.
The process data is represented on an LC display with 4 lines and 20 characters. Devices with a VF display are
available as an option. Various display languages can be selected.
In addition to the digital and bar indications on the display, the ACTUAL temperature of the heatsealing band is
supplied to an analog 0…10VDC output. The real heatsealing band temperature can thus be displayed on an
external temperature meter (e.g. ATR-x).

Accessories and modifications
The RESISTRON® temperature controller RES-440 also features an integrated fault diagnosis function, which
tests both the external system (heatsealing band, wiring etc.) and the internal electronics and outputs a selective
error message in case of a fault.
To increase operational safety and interference immunity, all 24VDC logic signals are electrically isolated from the
controller and the heating circuit.
The menu in the temperature controller itself can be used to adapt to different heatsealing band alloys (Alloy A20,
LEX3500 etc.) and set the required temperature range (0…300°C, 0…500°C etc.).
The RESISTRON® temperature controller RES-440 is designed for installation in a front panel cutout. The com-
pact design and the plug-in connections make this controller easy to install.
5 Accessories and modifications

A wide range of compatible accessories and peripheral devices are available for the RESISTRON® temperature
controller RES-440. They allow it to be optimally adapted to your specific heatsealing application and to your
plant's design and operating philosophy.
5.1 Accessories
The products described below are only a few of the wide range of accessories available for RESISTRON® tem-
perature controllers ("Accessories" leaflet).
Analog temperature meter ATR-x

For front panel mounting or mounting on a top hat rail (DIN TS35).
Analog indication of the ACTUAL temperature of the heatsealing band in °C. The
meter damping of the unit is optimized for the abrupt temperature changes that occur
in impulse mode.
Digital temperature meter DTR-x

For front panel mounting or mounting on a top hat rail (DIN TS35).
Digital indication of the ACTUAL temperature of the heatsealing band in °C, with
HOLD function.
Line filter LF-xx480

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

Designed according to 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 temper-
atures 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).
Adapter for top hat rail mounting, HS-Adapter-01

For mounting the RESISTRON® temperature controller RES-440 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 author-
ized 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)
Owing to its universal design, the RESISTRON® temperature controller RES-440 is suitable for a very wide range
of heatsealing applications.
Modifications (MOD) are available for the RESISTRON® temperature controller RES-440 for implementing special
applications.

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 33
(Software revision 010 or higher)
Important heatsealing process data can be output and logged via a serial RS232 interface ( MOD 33" documen-
tation).
This modification is only recommended for existing applications. The PC visualization software
! ( section 10.21 "Diagnostic interface/visualization software (as of software revision 100)" on
page 63) should be used for all new applications.

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 March 2006

(as of software revision 100):
115VAC version: 110VAC -15%…120VAC +10% (equivalent to 94…132VAC)
All controllers manufactured as of January 2004 up to February 2006

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

115VAC, 230VAC or 400VAC, tolerance: +10% / -15%
depending on device version ( section 13 "How to order" on page 86)
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 A20):
0…200°C, 0…300°C, 0…400°C, 0…500°C
Temperature coefficient 3500ppm (e.g. LEX3500):
0…200°C, 0…300°C
Set point selection Via the Settings menu in the controller
Analog output 0…10VDC, Imax = 5mA

(actual value) Equivalent to 0…300°C or 0…500°C
Terminals 23+24 Accuracy: ±1% add. 50mV

Technical data
Digital logic levels LOW (0V): 0…2VDC

Terminals 3, 4, 22 HIGH (24VDC): 12…30VDC (max. current input 6mA)
Electrically isolated, reverse polarity-protected
START with contact Switching threshold: 3.5VDC, Umax = 5VDC, Imax = 5mA
Terminals 2+7
Switching output Umax = 30VDC, Imax = 50mA

for „"Output 1"/ UON < 2V (saturation voltage)
Temp. OK" signal Transistor conductive if the temperature is inside the tolerance band.
Terminals 20+21
Alarm relay Contact, potential-free, Umax = 30V (DC/AC), Imax = 0.2A

Terminals 5+6
Relay K1 Changeover contact, potential-free, Umax = 240VAC/100VDC, Imax = 1.5A

Terminals 16, 17, 18 Interference suppression with 47nF / 560ohms for each terminal
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.

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 terminal wires
terminal blocks
66
72
terminal blocks
front frame front panel terminal wires

9 132 29
DIP-switch
to select
136
144
U2, I2

Installation
8 Installation
 See also section 1 "General information" on page 4.
Installation and startup may only be performed by technically trained, skilled persons who are
! familiar with the associated risks and warranty provisions.
8.1 Installation procedure
Proceed as follows to install the RESISTRON® temperature controller RES-440:

1. Switch off the line voltage and verify that all circuits are deenergized.
2. The supply voltage specified on the nameplate of the RESISTRON® temperature controller must be identical
to the line voltage that is present in the plant or machine. The line frequency is automatically detected by the
temperature controller in the range from 47Hz to 63Hz.
3. Install the RESISTRON® temperature controller in the front panel cutout. It is fastened by means of two clips
which snap onto the side of the controller housing.
4. Wire the system in accordance with the instructions in section 8.3 "Power supply" on page 18, section 8.6
"Wiring diagram (standard)" on page 21 and the ROPEX Application Report. The information provided in
section 8.2 "Installation steps" on page 17 must 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.

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)

Installation
8.3 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
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
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.

Installation
8.4 Line filter
To comply with EMC directives – corresponding to EN 50081-1 and EN 50082-2 – RESISTRON control loops
must be operated with line filters.
These filters damp the reaction of the phase-angle control on the line and protect the controller against line 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 8.3 "Power supply" on page 18 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
8.5 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 8.3 "Power supply" on page 18).

Installation
8.5.1 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)
8.5.2 PEX-W5
Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (DIN EN 50022).

Installation
8.6 Wiring diagram (standard)

14
RES-440 LINE
(also with MOD 01) 15
17
RELAY K1
100VDC/1.5A
16 1 +
240VAC/1.5A K1
2 0V
18
2x 47nF/560R
6 13
ALARM
OUTPUT
max. 30V/0.2A 12
5
Contact closed or U1
opened by ALARM prim.
(see configuration) Impulse
21
transformer
U2
GND 20 sec.
PREHEAT
22 11 Heat-
with 24VDC signal UR R sealing
0V 10 band
START (HEAT) (Intern.ground) twisted
with 24VDC signal 3 No external
grounding 9
allowed! IR
GND 4 8
Current transformer
Ground up to
for 24VDC signals. production date
Must be grounded February 2006
externally to prevent 0V (Internal ground)
electrostatic Terminal 2
charging! 0V
(Intern.ground)
_ No external START (HEAT)
23 grounding 7 with contact
ATR
°C + allowed!
24 0V PREHEAT
ANALOG (Internnal ground) 19 (Vorwärme)
OUTPUT No external grounding allowed! with contact
+0...10VDC
25 26
NC NC
Terminals 19, 25 and 26 are only available in devices supplied as of October 2002.
!

Installation
8.7 Wiring diagram with booster

connection

14
RES-440 LINE
(also with MOD 01) 15
17 Booster
RELAY K1 3 1
100VDC/1.5A
16 + 1
IN OUT
240VAC/1.5A K1 0V
2
18 4 2
2x 47nF/560R
6 13 NC
ALARM
OUTPUT
max. 30V/0.2A 12 NC
5 U1
Contact closed or
opened by ALARM prim.
(see configuration) Impulse
21
transformer
U2
GND 20 sec.
PREHEAT
22 11 Heat-
with 24VDC signal UR R sealing
0V 10 band
START (HEAT) (Intern.ground) twisted
with 24VDC signal 3 No external
grounding 9
allowed! IR
GND 4 8
Current transformer
Ground up to
for 24VDC signals. production date
Must be grounded February 2006
externally to prevent 0V (Internal ground)
electrostatic Terminal 2
charging! 0V
(Intern.ground)
_ No external START (HEAT)
23 grounding 7 with contact
ATR
°C + allowed!
24 0V PREHEAT
ANALOG (Internnal ground) 19 (Vorwärme)
OUTPUT No external grounding allowed! with contact
+0...10VDC
25 26
NC NC
Terminals 19, 25 and 26 are only available in devices supplied as of October 2002.
!

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
19 20 21 22 23 24 25 26 ROPEX RES-440 16 17 18
(only with filter)
19 20 21 22 23 24 25 26 16 17 18
CONTACT
PREHEAT
PREHEAT
U2 U1
TEMP. OK
0V K1
GND
R SEC. PRIM.
24VDC
TEMP.OUT
N (L1)
0 -10VDC
AUTO UR 0,4 - 120V FILTER L1 (L2)
(PE)
CONTACT
RANGE I2 30 - 500A
START
START
BOOSTER 24VDC ALARM

0V UR
GND IR 12 13 14 15
DIAG
1 2 3 4 5 6 7 8 9 10 11
1 2 3 4 5 6 7 8 9 10 11
30V / 0,2A
Terminals Diagnostic interface Terminals

Printed wiring diagram
19 20 21 22 23 24 25 26 ROPEX RES- 440 16 17 18
(only with filter)

DIP-SWITCH
ON 1 2 3 4 5 I2 ( A )
OFF OFF 30 - 100
U2 ( V ) 1-10 6-60 20-120 ON OFF 60 - 200
19 20 21 22 23 24 25 26 ON ON 120 - 400 16 17 18
PREHEAT
PREHEAT U2 U1
GND
TEMP. OK
K1
Contact
24VDC 0V R SEC. PRIM.

TEMP.OUT N (L1)
0 -10VDC
FILTER L1 (L2)
(PE)
Contact
START
START
BOOSTER 24VDC ALARM
0V UR
GND IR 12 13 14 15
1 2 3 4 5 6 7 8 9 10 11 DIP-SWITCH
1 2 3 4 5 6 7 8 9 10 11 OFF
1 2 3 4 5 ON
12345
50V / 0,2A
Terminals DIP switches Terminals
Terminals 19, 25 and 26 are only available in devices supplied after October 2002.
!
9.3 Controller configuration
The possible controller configurations are explained in the following sections. Proceed as described in
section 9.5.1 "Initial startup" on page 33 to start up the controller for the first time.
9.3.1 Configuration of the DIP switches for secondary voltage and current
The controller must be switched off in order to configure the DIP switches.
!
Automatic configuration (AUTORANGE)
(as of software revision 100)
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, a detailed error message appears
on the controller ( s. section 10.26 "Fault areas and causes" on page 81).
Configuration with coding switches

(up to software revision 027)
Set the DIP switches for matching the secondary voltage U2 and the secondary current I2 to the correct position
for your application.
You can find the exact configuration of the DIP switches in the ROPEX Application Report calculated
! for your particular application.

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 secondary high-current wire must be laid twice (or several times)
through the PEX-W2 or PEX-W3 current transformer ( ROPEX Application Report).
2x
9.3.2 Setting the language

The menu language can be changed on the controller without interrupting operation. It is set with step 20 in the
Configuration menu:
The following settings are possible:
English, German, Italian
Software revision 015 or higher also:
French, Spanish, Dutch, Danish, Finnish, Swedish, Greek, Turkish.
Software revision 024 or higher also: Portuguese.
The language which is selected in this menu remains set even if the factory settings are restored
! (step 202 [21] in the Configuration menu).
As of software revision 103, the language setting with step 202 can still be changed even if the Con-
! figuration menu is disabled .
9.3.3 Restoring the factory settings

The internal controller settings can be reset to the factory settings with step 202 [21] in the Configuration menu.
Only the language setting (step 201 [20] in the Configuration menu) remains unchanged.
Please refer to section 11 "Factory settings" on page 83 for more information about the factory settings.
If the controller settings are unknown when it is started up for the first time, the factory settings
! must be restored in order to prevent malfunctions.
9.3.4 Configuration of the alloy and the temperature range (up to software
revision 027)
These parameters are set with step 22 in the Configuration menu:

Several different ranges can be selected:

1. Temperature coefficient 410ppm, 0…300°C
(software revision 021 or higher)
(e.g. Alloy L, software revision 011 or higher)
10.Temperature coefficient 780ppm, 0…500°C
(e.g. Alloy A20)
(Factory settings)
(e.g. Alloy A20)
(e.g. Alloy A20)
(e.g. Alloy A20)
(e.g. LEX3500)
(e.g. LEX3500)
9.3.5 Configuration of the alloy (Temperature coefficient) (as of software revision 100)
The heatsealing band alloy (and the temperature coefficient respectively) can be set with steps 203 and 204 in the
Configuration menu.
In step 203 predefined values for the alloy (and the temperature coefficient repsecitvely) are available:
1. Temperature coefficient 780ppm
(e.g. Alloy L)
(Factory setting)
(e.g. Alloy A20)


(e.g. ROPEX CIRUS system)
(e.g. ROPEX CIRUS system)
(e.g. LEX3500)
6. Temperature coefficient „variable“
Further settings in step 204.
In step 204 the temperature coefficent can be set in a range of 400…4000 ppm individually for the used heat-
sealing band then.
Step 204 in the Configuration menu is available when step 203 is set to "variable" only.
!
9.3.6 Configuration of the temperature range (as of software revision 100)

The temperature range can be set with steps 205 in the Configuration menu.
The setting can be 200°C, 300°C (Factory setting), 400°C or 500°C.
9.3.7 Configuration of the timer function
The necessary controller settings are explained in the detailed functional descriptions in
! section 10.6 "Menu steps" on page 42 and section 10.23 "Time control (timer function)" on page 64.
They are only allowed to be entered by technically trained persons.
The timer function is activated with step 26 in the Configuration menu.
9.3.8 Relay K1 (without time control)

The function of relay K1 is specified with step 212 [29] in the Configuration menu. The following settings are pos-
sible when time control is deactivated:
1. "Off" (Factory setting)
Relay K1 has no function
2. "Active if Tact = Tset"
Relay K1 is activated if the actual value is inside the specified temperature tolerance band (steps 207 [24],
208 [25]). If the actual temperature is outside the tolerance band, relay K1 is deactivated (see graph below).
Actual value
Set+ Δϑ upper
Set
Set+ Δϑ lower
Time
Output
Relay K1
closed
open
Time

3. "Active if Tact = Tset", with latch function

Relay K1 is closed if the actual value is inside the specified temperature tolerance band (steps 207, 208). If the
actual temperature leaves the tolerance band once while the "START" signal is active, relay K1 is opened. The
relay is not closed again until the next "START" signal is activated. The switching state of relay K1 can thus
also be interrogated by the higher-level PLC after a heatsealing process (latch function, see graph below).
Actual value
Set+ Δϑ upper
Set
Set+ Δϑ lower
Time
NO contact of
Relay K1
Closed
Open
Time
Other settings are available in this menu when time control (timer function) is active. They are described in
section 10.23.7 "Relay K1 (with time control)" on page 70.
9.3.9 “Output 1“/ “Temperature OK“ signal (without time control)
On controllers up to software revision 027, the switching output at terminals 20+21 was called
! "Temperature OK". The more general name "Output 1" is used as of software revision 100 because
this output now also supports other functions.
The "Output 1" signal is available at terminals 20+21 as a digital control signal.
+24VDC
RES-440
21
Imax 50mA
20
GND
GND

The RES-440 checks whether the ACTUAL temperature is inside a specifiable tolerance band ("OK" window) on
either side of the SET temperature. The lower ( Δϑ lower ) and upper ( Δϑ upper ) limits of the tolerance band can be
changed independently of one another by means of steps 24+25 in the Configuration menu.
If the actual temperature is inside the specified tolerance band, the output signal at terminals 20+21 is switched
(see graph below):

Actual value
Set+ Δϑ upper
Soll
Set+ Δϑ lower
Time
"Output 1"
Terminals 20+21
Conductive
Not conduct.
Time
The ACTUAL temperature is evaluated, and the output signal at terminals 20+21 activated, in all
! operating states except when a fault is signaled.


If time control (timer function) is deactivated, the same configuration options are available for "Output 1" as for
relay K1 ( section 9.3.8 "Relay K1 (without time control)" on page 27). The options for "Output 1" are specified
with step 222 in the Configuration menu as followed:
1. "Off"
"Output 1" has no function
Output 1 is conductive if the actual value is inside the specified temperature tolerance band (steps 207, 208).
If the actual temperature is outside the tolerance band, "Output 1" is not conductive.
This function is the same as for the "Temperature OK" signal up to software revision 027.
(factory setting)
"Output 1" is conductive if the actual value is inside the specified temperature tolerance band (steps 207, 208).
If the actual temperature leaves the tolerance band once while the "START" signal is active, "Output 1 is no
longer conductive. "Output 1" does not become conductive again until the next "START" signal is activated and
can thus also be interrogated by the higher-level PLC after a heatsealing process.
Other settings are available in this menu when time control (timer function) is active. They are described in
section 10.23.8 "“Output 1“/ “Temperature OK“ signal (with time control)" on page 72.
9.3.10 Temperature diagnosis (as of software revision 100)

The temperature diagnosis function can be activated by means of step 217 in the Configuration menu. The
RES-440 then checks whether the ACTUAL temperature is inside a specifiable tolerance band ("OK" window) on
either side of the SET temperature. The lower ( Δϑ lower ) and upper ( Δϑ upper ) limits of the tolerance band can be
changed independently of one another by means of steps 207 [24] + 208 [25] (factory setting: -10K or +10K).
If the ACTUAL temperature is inside the specified tolerance band when the "START" signal is activated, the tem-
perature diagnosis is also activated. If the ACTUAL temperature leaves the tolerance band, the corresponding
error code (307, 308) is indicated and the fault output is switched ( section 10.26 "Fault areas and causes" on
page 81). If a heatsealing cycle is in progress, it is immediately interrupted.
Actual value
Set+ Δϑ upper
Set
Set+ Δϑ lower
Time
Error code
307
If the temperature diagnosis is not activated by the time the "START" signal is deactivated (i.e. if the ACTUAL tem-
perature does not exceed the upper or lower tolerance band limit), the corresponding error code (309, 310) is indi-
cated and the fault relay is switched.
If the temperature diagnosis function is activated, an additional delay time of 0 to 9.9s can be parameterized for
the temperature timeout with step 218 in the Configuration menu. The first time the lower tolerance band limit is
exceeded, the temperature diagnosis is not activated until the parameterized delay time has elapsed. The tem-

perature diagnosis function can thus be explicitly deactivated, e.g. if the temperature drops temporarily owing to
the closure of the sealing jaws.
9.3.11 Heatup timeout (as of software revision 100)

The heatup timeout can be parameterized with step 219 in the Configuration menu ("0" = OFF).
This timeout starts when the START signal is activated. The RES-440 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 fault relay is switched ( section 10.26 "Fault areas and
causes" on page 81).
Actual value
Set
95% of Set
Timeout
Time
Heatup time Error code
304
9.3.12 Configuration of the alarm relay

The alarm relay is set with step 215 [31] in the Configuration menu.
There are two possible settings:
1. "Normal" (Factory setting)
Alarm relay contact closed by a fault
2. "Inverse"
Alarm relay contact opened by a fault
9.4 Heatsealing band
9.4.1 General
The heatsealing band is a key component in the control loop, since it is both a heating element and a sensor. The
geometry of the heatsealing band is too complex to be discussed at length here. We shall therefore only refer to
a few of the most important physical and electrical properties:
The measuring principle applied for this system necessitates a heatsealing band alloy with a suitable temperature
coefficient TCR, i.e. one whose resistance increases as the temperature rises.
Too low a TCR leads to oscillation or uncontrolled heating.
When heatsealing bands with a higher TCR are used, the controller must be calibrated for this.
The first time the heatsealing band is heated to approximately 200…250°C, the standard alloy undergoes a once-
only resistance change (burn-in effect). The cold resistance of the heatsealing band is reduced by approximately
2…3%. However, this at first glance slight resistance change results in a zero point error of 20…30°C. The zero
point must therefore be corrected after a few heating cycles ( chap. 9.4.2 „Burning in the heatsealing band“,
page 32).

One very important design feature is the copper or silver-plating of the heatsealing band ends. Cold ends allow
the temperature to be controlled accurately and increase the life of the teflon coating and the heatsealing band.
An overheated or burned-out heatsealing band must no longer be used because the TCR has been
! altered irreversibly.
9.4.2 Burning in the heatsealing band

If a new heatsealing band has been used, the zero point is first of all calibrated while the band is still cold by acti-
vating the "AUTOCAL" function on the controller. When the "AUTOCAL" function has finished, the controller out-
puts the preselected calibration temperature (default value: 20°C). Adjust the set point to approximately 250°C
and press the "HAND" key (display in home position) to heat for approximately 1 second. After recooling, the con-
troller usually indicates a value less than 20°C. Repeat the "AUTOCAL" function. The heatsealing band has now
been burned in and the change in the alloy properties stabilized.
The burn-in effect described here does not occur if the heatsealing band has already been thermally pretreated
by the manufacturer.
9.4.3 Replacing the heatsealing band

All power supply leads must be disconnected from the RESISTRON® temperature controller in order to replace
the heatsealing band.
The heatsealing band must be replaced in accordance with the instructions provided by the 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 must be performed for all new heatsealing bands.

9.5 Startup procedure
Please also refer to section 1 "General information" on page 4 and section 2 "Application" on page 8.
Installation and startup may only be performed by technically trained, skilled persons who are
! familiar with the associated risks and warranty provisions.
9.5.1 Initial startup

Prerequisites: The controller must be correctly installed and connected ( section 8 "Installation" on page 16).
The possible settings are described in detail in chap. 9.3 „Controller configuration“, page 24 and chap. 10 „Con-
troller functions“, page 34.
The essential controller configurations are described below:
1. Switch off the line voltage and verify that all circuits are deenergized.
2. The supply voltage specified on the nameplate of the controller must be identical to the line voltage that is
present in the plant or machine. The line frequency is automatically detected by the temperature controller in
the range from 47 to 63Hz.
3. In case of controllers up to software revision 027, the setting of the DIP switches on the controller are indicated
in the ROPEX Application report and depend on the heatsealing band (section 9.3 "Controller configuration"
on page 24).
4. Make sure that a START signal is not present.
5. Switch on the line voltage.
6. A power-up message appears on the display for approximately 2 seconds when the controller is switched on
to indicate that it has been started up correctly.
7. One of the following states then appears:
DISPLAY ACTION
Main menu Go to 8
Error message with error codes Go to 8

104…106, 111…113, 211
Error message with error codes Fault diagnosis

101…103, 107, 108, ( 10.26)
201…203, 801, 9xx
8. Set the controller configuration as described in section 9.3 "Controller configuration" on page 24. The following
settings are always required:
Step in Con-
Setting figuration
menu
Language 201 [20]
Restore factory settings 202 [21]
Temperature range and heat- 203, 204, 205

sealing band alloy [22]
9. Activate the AUTOCAL function while the heatsealing band is still cold (with step 7 in the Settings menu). The
progress of the calibration process is indicated by a counter on the display (approx. 10…15s). A voltage of app.

Controller functions
0VDC appears at the same time at the actual value output (terminals 23+24). If an ATR-x is connected, it indi-
cates 0…3°C.
When the zero point has been calibrated, the display is reset to the home position and 20°C is indicated as the
actual value. A voltage of 0.66VDC (for the 300°C range) or 0.4VDC (for the 500°C range, equivalent to 20°C,
appears at the actual value output. If an ATR-x is connected, it must be set to "Z" (20°C).
If the zero has not been calibrated successfully, an erro message indicates error codes 104…106, 211. In this
case the controller configuration is incorrect ( section 9.3 "Controller configuration" on page 24 and ROPEX
Application Report). Repeat the zero point calibration after the controller has been configured correctly.
10.When the zero point has been calibrated successfully, the main menu appears on the display again. Then
specify a defined temperature (heatsealing temperature) with step 1 in the Settings menu and activate the
"START" signal (HEAT). Alternatively, a heatsealing process can be started by pressing the "HAND" key (dis-
play in home position). The indication of the ACTUAL temperature on the display (digital value and dynamic
bar) permits the heating and control process to be monitored.
The controller is functioning correctly if the temperature indicated on the display has a continuous curve, 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 wire has been laid incorrectly.
If an error code is displayed, please proceed as described in section 10.26 "Fault areas and causes" on
page 81.
11. Burn in the heatsealing band ( section 9.4 "Heatsealing band" on page 31) and repeat the AUTOCAL func-
tion.
The controller is now

ready
9.5.2 Restart after replacing the heatsealing band

To replace the heatsealing band, proceed as described in section 9.4 "Heatsealing band" on page 31.
Always use a heatsealing band with the correct alloy, dimensions and copper-plating in order to
! avoid malfunctions and overheating.
Continue with section 9.5.1, steps 9 and 10.
10 Controller functions
See also section 8.6 "Wiring diagram (standard)" on page 21.

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
10.2 Display
10.2.1 Power-up message

A power-up message appears on the display for approximately 2 seconds when the controller is switched on. This
message also includes details of the software version.
Company name
(optional: customer-specific)
Software ID number
Controller type (RES-440)

10.2.2 Display in home position

If no settings are entered on the controller and no error message are present, the display is in the home position,
in other words it indicates the SET temperature as a digital value and the ACTUAL temperature as a digital value
and a dynamic bar. If time control (timer function) is active, the time control settings are also displayed.
Specified heatsealing Icon indicates that NO Measured ACTUAL

temperature contact of additional temperature
(SET temperature) relay K1 is closed.
ACTUAL temperature
as a dynamic bar
Heatsealing parameters
(only if time control is active)
Cooling parameters
(only if time control is active)
10.2.3 Settings/Configuration menus

The required parameters are set on two menu levels: the Settings (control) menu and the Configuration menu
( section 10.4 "Menu structure" on page 39).
Menu level: Position in menu

Settings or Configuration menu (menu step)
(Configuration menu shown here)
Menu contents
(max. 3 lines)
10.2.4 Error messages

The fault diagnosis function of the controller is always active. If a fault is detected, it is indicated on the display
immediately in the form of an error message ( section 10.24 "System monitoring/alarm output" on page 76).
Alarm indication
Fault description
and error code
Prompt to press
"RESET" key

10.3 Navigation in the menus
10.3.1 Navigation in menus without a fault

A "MENU" key is provided for navigating through the various menu steps and levels. By pressing this key briefly
(<1s) at any time, you can jump to the next menu step. As of software revision 100, you can also jump to the pre-
vious menu step by pressing the "MENU" key for 1-2s. By pressing the key for longer (>2s), you can return to the
home position from anywhere in the menu structure, providing a controller alarm is not active. In this case, the
Alarm menu is opened instead.
If the display is in the home position or an alarm is indicated and you press the "MENU" key for longer than 2s,
you are taken directly to the configuration level (starting at step 201 [20]).
In addition, you always return to the home position if you do not press any keys for a period of 30s. There is no
automatic return after 30s from "AUTOCAL" or "Alarm".
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

10.3.2 Navigation in menus with a fault

If an alarm is signaled, the controller switches to the Alarm menu. Some faults can be acknowledged by pressing
the "RESET" key ( section 10.24 "System monitoring/alarm output" on page 76). In this case, the controller
switches back to the home position.
If the fault can be rectified by executing the AUTOCAL function, you can select the "AUTOCAL" menu step directly
by briefly pressing the "MENU" key (<2s). You can then activate the "AUTOCAL" function by pressing the
"ENTER" key ( section 10.9 "Automatic zero calibration (AUTOCAL)" on page 53).
If you press the "MENU" key for longer than 2s in the Alarm menu, you are taken directly to the configuration level
(starting at step 201 [20]). You can return from the Configuration menu to the Alarm menu either by pressing the
"MENU" key for longer than 2s or by not pressing any keys for 30s.
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

10.4 Menu structure
Settings Configuration
Power-up message
Home position 201 Language

1) Time control: ON
2) Time control: OFF
101 Heatsealing temp. 202 Factory settings
3) AUTOCOMP: OFF
4) AUTOCOMP: ON
102 Preheating temp. 203 Alloy 5) TCR variable
1) 2) 5) 6) 6) TCR not variable
103 Starting delay 204 Temp. coefficient 7) Cooling mode: abso-
lute, relative, time
8) Cooling mode: none
104 Sealing time 205 Temperature range
7) 8)
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

Configuration
Continued from previous page
219 Heatup timeout
220 Meas. imp. length
221 Autocomp
222 "Output 1"
225 Temperature unit
Back to home position

10.5 Two-digit numbering system up to software revision 027
A system of one and two-digit numbers was used for the Settings and Configuration menus up to software
revision 027. Three-digit numbers were introduced in software revision 100 to improve the clarity of the menu
structure.
The table below compares the two numbering systems:
Numbering Numbering
Menu Menu steps up to software as of software
revision 027 revision 100
Settings menu Heatsealing temperature 1 101
Preheating temp. (PREHEAT) 2 102
Starting delay 3 103
Heatsealing time 4 104
Cooling value 5 105
Hold mode 6 106
AUTOCAL 7 107
Configuration menu Language 20 201
Factory settings 21 202
Alloy / TCR 22 203, 204
Maximim temperature 23 206
Set point reached 24 207
Set point exceeded 25 208
Time control 26 209
Cooling mode 27 210
Sart of heatsealing time 28 211
Relay K1 function 29 212
Cycles 30 214
Alarm relay 31 215
Measuring pulse length 32 220
Analog output 33 216
All number sor menu steps not listed above are only available as of software revision 100 and are
! described in chap. 9 „Startup and operation“, page 23 (and section 10.4 "Menu structure" on
page 39 respectively).
The new, three-digit menu step numbers are described first in all relevant sections of this document.
! The older, two-digit numbers are indicated afterwards in square brackets (e.g. step 201 [20]).

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 heat-
sealing time and the cooling value are also dis-
played.
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.
102 Preheating temper- The required preheating temperature can be set Depends on setting of
[2] ature with the "UP" and "DOWN" keys. The maximum step 205 [22]:
temperature (step 206 [23]) applies to both the 0, 40°C…maximum tem-
heatsealing temperature and the preheating temperature (step 206 [23])
perature.
The preheating function can be deactivated by
entering 0°C.
103 Starting delay This option allows the heatsealing time to be 0…9.9s
[3] preceded by a starting delay. This delay time begins
as soon as the start signal is applied. When it
elapses, the heatsealing time is activated.
This function can only be selected if time control
(step 209 [26]) is active.
104 Heatsealing time The length of the heatsealing pulse can be set with 0…99.9s, EXT
[4] the "UP" and "DOWN" keys. The specified heat-
sealing time is indicated in the home position.

105 Cooling value The cooling value can be specified here according
[5] to the cooling mode (absolute, relative, time)
selected with step 210 [27].
• Absolute: The cycle ends if the "cooling tem- 50°C to maximum temper-
perature" falls below the set value (in °C). ature (step 206 [23])
• Relative: The cycle ends if the "cooling tempera- 40%…100%

ture" falls below the set percentage value,
whereby 100% corresponds to the specified set
point (step 101 [1]).
• Time: The cycle ends when the set "cooling time" 0…99.9s
in seconds has elapsed. The current cooling
value is indicated in the home position.
106 Hold mode If the "Hold" function is activated, the last measured ON
[6] 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

[7] 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.

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 83).
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

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 and the analog output. 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 heat-
sealing 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
displayand the analog output.
206 Maximum This menu item specifies the maximum selectable 0 to max. temperature
[23] temperature set point (step 101 [1]) and the maximum selectable range (step 205 [22])
preheating temperature (step 102 [2]) within the
range defined by step 205 [22].

207 Set point reached As of software revision 100: -5K…-99K

[24] (low limit) If the actual value is greater than the switching
threshold specified here and less than the threshold
set with step 208, "Output 1" and/or relay K1 can be
activated depending on the configuration (step 212
or 222).

If the actual value is greater than the switching
threshold specified here and less than the threshold
set with step 25, the "Temperature OK" output is
activated.
The value is entered in Kelvins (K) and subtracted

from the set point in order to calculate the switching
threshold.
208 Set point exceeded As of software revision 100: +5K…+99K

[25] (upper limit) If the actual value is less than the switching
threshold specified here and greater than the
threshold set with step 207, "Output 1" and/or relay
K1 can be activated depending on the configuration
(step 212 or 222).

If the actual value is less than the switching
threshold specified here and greater than the
threshold set with step 24, the "Temperature OK"
output is activated.
The value is entered in Kelvins (K) and added to the

set point in order to calculate the switching
threshold.
209 Time control This menu step specifies whether the controller ON,
[26] should operate with or without time control. ON with START moni-
toring,
OFF

210 Cooling mode The end of the cooling-down phase (end of cycle)
[27] can be configured by specifying the required cooling
mode.
• Absolute: The cycle ends if the actual value falls Absolute (in °C)
below the cooling temperature set here.
• Relative: The cycle ends if the actual value falls Relative (in %)
below the relative cooling temperature (per-
centage of the set point) set here.
• Time: The cycle ends when the set cooling time Time (in s)
has elapsed.
211 Start of heatsealing This menu step specifies whether the heatsealing Heatsealing time starts
[28] time time (step 104 [4]) should begin as soon as the start when heating starts
signal is applied or when 95% of the set point is
reached. Heatsealing time starts
This function can only be selected if time control when temperature
(step 209 [26]) is active. reached
212 Relay K1 function The energizing behavior of relay K1 can be config-

[29] ured as follows:
Time control OFF:
• K1 is not activated Relay K1 OFF
• Relay K1 is energized if the actual value is inside Relay K1 active if Tact =

the specified temperature tolerance band (steps Tset
207 [24], 208 [25]).

• In addition, as of software revision 100: Relay K1 active if Tact =

K1 is energized if the actual value is inside the Tset, with latch function
specified temperature tolerance band
(steps 207, 208). The relay remains energized at
the end of the heatsealing cycle and is not deen-
ergized again until the next "START" signal is
activated.
Time control ON:
• K1 is not activated Relay K1 OFF
• K1 is energized if the start signal is present. The Relay K1 active when

relay is deenergized at the end of the cooling START signal present
phase.
• K1 is energized if the actual value reaches 95% Relay K1 active when

of the set point. The relay is deenergized at the temperature reached
end of the cooling phase.
• K1 is energized at the end of the heating phase Relay K1 active during

and deenergized again at the end of the cooling cooling phase
phase.
(This setting is possible as of software
revision 010)
• K1 is energized for up to 0.5 seconds at the end Relay K1 generates end-

of the cooling phase (momentary impulse). The of-cycle impulse
length of the momentary impulse can be short-
ened by applying the start signal (during the
impulse).

K1 is energized if the actual value is inside the Tset
(steps 207, 208).

K1 is energized if the actual value is inside the Tset, with latch function
activated.
213 Lock of "HAND" key You can specify here whether or not the heatsealing ON,
band can be heated in the home position by OFF
pressing the "HAND" key.
214 Cycle counter The number of heating impulses (not manual Reset with "ENTER" key
[30] 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.

215 Alarm relay This menu step permits the switching characteris-
[31] tics 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.
216 Analog output This menu step determines whether the current Real temperature,
[33] actual value or a 10V reference voltage is output at 10V reference
the actual value output (terminal 24).
(This setting is possible as of software
revision 017).
The 10V reference can be used for the connection
of an external potentiometer as temperature preset.
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
[32] length changed here. This function is only available with a
few special applications (MOD 1).
221 Autocomp Activates the „AUTOCOMP“ function OFF,

ON
222 "Output 1" The energizing behavior of output 1 can be config-

ured as follows:
Time control OFF:
• Output 1 is not activated "Output 1" OFF
• Output 1 is energized if the actual value is inside "Output 1" active if Tact =
the specified temperature tolerance band Tset
(steps 207, 208).

the specified temperature tolerance band Tset, with latch function
activated.
Time control ON:
• Output 1 is not activated "Output 1" OFF
• Output 1 is energized if the start signal is "Output 1" active with

present. The relay is deenergized at the end of START signal
the cooling phase.
• Output 1 is energized when the actual value "Output 1" active when
reaches 95% of the set point. The relay is deen- temperature reached
ergized at the end of the cooling phase.
• Output 1 is energized at the end of the heating "Output 1" active during
phase and deenergized again at the end of the cooling phase
cooling phase.
(This setting is possible as of software revision
010)
• Output 1 is energized for up to 0.5 seconds at "Output 1" generates end-

the end of the cooling phase (momentary of-cycle impulse
impulse). The length of the momentary impulse
can be shortened by applying the "START"
signal (during the impulse).
the specified temperature tolerance band Tset
(steps 207, 208).
the specified temperature tolerance band Tset, with latch function
activated.
225 Temperature unit Unit for temperature display and input values Celsius
Fahrenheit
10.7 Temperature setting (set point selection)
The heatsealing temperature can be set on the RES-440 controller by means of the setting in menu step 101 [1].
The maximum value of the setting range is limited either by the maximum value specified 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 temperature must be greater than 40°C. If not, the heatsealing
band will not be heated up when the "START" signal is activated or the "HAND" key is pressed.
The set heatsealing temperature is displayed in the main menu once it has been entered.

10.8 Temperature indication/actual value output
If the display is in the home position, the ACTUAL temperature is indicated there as a digital value and as a
dynamic bar.
The heating and control process can thus be monitored at any time.
In addition, the RES-440 controller outputs an analog 0…10VDC signal, which is proportional to the real ACTUAL
temperature, at terminals 23+24
RES-440
Actual value R=33ohms max. 5mA
output 24
0…10VDC
0V 23
0…10VDC
- +
Temperature
meter
e.g. ATR-3
Voltage values:
0VDC  0°C
10VDC  300°C or 500°C (depending on the
controller configuration).

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"
Only the two temperature ranges 300°C and 500°C appear at this actual value output. If a temperature range of
200°C is set for the controller with step 205 [22] in the Configuration menu, it appears at this output in the
0…300°C range. A 400°C temperature range is indicated as 0…500°C.
An indicating instrument can be connected to this output in order to visualize the temperature of the heatsealing
band.
The characteristics of the ROPEX ATR-x temperature meter (size, scaling, dynamic response) are ideally suited
to this application ( section 5 "Accessories and modifications" on page 10).
It not only facilitates SET-ACTUAL comparisons, but also enables other criteria such as the heating rate, set point
reached within the specified time, cooling of the heatsealing band etc. to be evaluated.
This meter moreover permits disturbances in the control loop (loose connections, contacting or wiring problems)
as well as any line disturbances to be observed extremely effectively and interpreted accordingly. The same
applies if mutual interference occurs between several neighboring control loops.

If a fault is signaled, this analog output is used – in addition to the value indicated on the controller – to display a
selective error message ( section 10.26 "Fault areas and causes" on page 81).
If you want a fixed 10V reference voltage to appear at the analog output (terminal 24), you can configure this in
the Configuration menu, step 216 [33] (analog output):
• Actual temperature (Factory setting)
The actual value output indicates the current ACTUAL value as a 0…10VDC analog voltage.
• 10V reference
(This setting is possible as of software revision 017)
A fixed 10VDC reference voltage is output at the actual value output.
This output is not potential-free and could have the potential of the secondary voltage of the impulse
! transformer. External grounding is not allowed. If this warning is ignored, the controller will be dam-
aged by frame currents. Contact voltage protection must be installed at the terminals of the external tem-
perature meter.
10.9 Automatic zero calibration (AUTOCAL)
Owing to the automatic zero calibration (AUTOCAL) function, there is no need to adjust the zero point manually
on the controller. The "AUTOCAL" function matches the controller to the current and voltage signals that are
present in the system.
You can activate this function by selecting step 107 [7] in the Settings menu and then pressing the "ENTER" key.
The initial temperature (ambient temperature) of the heatsealing bar(s) which is currently valid for calibration can
be set beforehand in the 0…40°C range using the "UP" and "DOWN" keys.
The zero point is calibrated in the factory to 20°C.
The automatic calibration process takes around 10…15 seconds. The heatsealing band is not heated until the cali-
bration process has finished.
The message "- Calibration - Please wait..." appears on the display while the "AUTOCAL" function is executing
and a counter counts down from 13 to 0. The actual value output (terminals 23+24) is set to 0…3°C (corresponds
to app. 0VDC) for the duration of the calibration process.
If the temperature of the heatsealing band varies on controllers as of software revision 100, the "AUTOCAL" func-
tion is executed a maximum of three times. If the function still cannot be terminated successfully, an error message
appears ( section 10.26 "Fault areas and causes" on page 81).
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 if the heatsealing band cools down at a rate of more than 0.1K/
second. This is additionally indicated with step 107 [7] in the Settings menu by the message "Heatsealing band
still hot! Please wait...".
2. If the "START" signal (24VDC or contact) or the "PREHEAT" signal (24VDC or contact) is activated, the
AUTOCAL function is not executed. As of software revision 024 this is additionally indicated with step 107 [7]
in the Settings menu by the message „Autocal locked ! (START-Sig. active)“ or „Autocal locked ! (PREHEAT-
Sig. active)“.

3. Directly after the controller is powered up, the AUTOCAL function cannot be activated if a fault with error code
101…103, 201…203, 801 or 9xx occurs ( section 10.26 "Fault areas and causes" on page 81). If the con-
troller has already operated correctly - a minimum of once - after powering up, the AUTOCAL function cannot
be activated with error codes 201…203, 801 or 9xx.
10.10 "START" signal (HEAT)
The heating process is activated by means of the "START" signal in different ways, depending on the time control
status (timer function) ( Configuration menu, step 209 [26]) :
1. Time control off (deactivated):
When the "START" signal is activated, the controller-internal set/actual comparison is enabled immediately and
the heatsealing band is heated up to the SET temperature. It remains at this temperature until the signal is
deactivated again. This process can also be started independently of the "START" signal by pressing the
"HAND" key while the display is in the home position.
2. Time control on (activated):
If time control (timer function) is on, activating the "START" signal starts the internally parameterized timeout.
The time at which the heatsealing band begins to heat up depends on the setting of this parameter. The
"START" signal must be deactivated again before the next timeout is activated.
Pressing the "HAND" key while the display is in the home position causes the heatsealing band to start heating
up immediately (as described in 1). The internal timeout is not started.
The "START" signal can be activated in two ways:
• By means of a 24VDC signal at terminals 3+4.
24VDC
START
(HEAT)
RES-440
+ 3
max. 6mA
GND
- 4
HIGH: ≥ 12VDC
START (HEAT)
or
LOW: ≤ 2VDC START TIMER

• By means of a control contact at terminals 2+7
max.
5mA RES-440
7
START
(HEAT)
with
contact
2 0V
The "START" signal is disabled as long as the AUTOCAL function is executing in the Settings menu
! (with step 107 [7]).
The set point that is selected for the heatsealing temperature (step 101 [1] in the Settings menu) must be greater
than 40°C. If not, the heatsealing band will not be heated up.
The alarm relay is switched if the "START" signal is activated while an error message is indicating error codes
104…105, 111…113 or 211 ( section 10.26 "Fault areas and causes" on page 81). The heatsealing band is like-
wise not heated.
If a "PREHEAT" signal is used, it is deactivated internally during the heating and control process. The heatsealing
band is not returned to the set preheating temperature until the "PREHEAT" signal is activated again at the end of
the control process for the main heat (section 10.11 ""PREHEAT" signal (preheating)" on page 55).
10.11 "PREHEAT" signal (preheating)
The heatsealing band can be heated to a specified preheating temperature with the "PREHEAT" function, in order
to shorten the temperature rise time to the selected SET temperature for time-critical applications.
The preheating temperature is set with step 102 [2] in the Settings menu. The "PREHEAT" signal can be activated
in two ways:
• By means of a 24VDC signal at terminals 20+22.
24VDC
PREHEAT RES-440
+ 22
max. 6mA
GND
- 20
HIGH: ≥ 12VDC
PREHEAT
LOW: ≤ 2VDC

• By means of a control contact at terminals 2+19

(only available in devices supplied after October 2002)
max.
5mA RES-440
19
PREHEAT
with
contact
2 0V
The "START" signal is disabled as long as the AUTOCAL function is executing in the Settings menu
! (with step 107 [7]).
The value that is selected for the preheating temperature (step 102 [2] in the Settings menu) must be greater than
40°C. If not, the heatsealing band will not be heated up.
The alarm relay is switched if the "PREHEAT" signal is activated while an error message is indicating error codes
104…105, 111…113 or 211 ( section 10.26 "Fault areas and causes" on page 81). The heatsealing band is like-
wise not heated.
If a "PREHEAT" signal is active, it is deactivated internally for the duration of a heating and control process that is
activated either by means of the "START" signal or by pressing the "HAND" key.
"PREHEAT"
signal
24VDC
0
"START" t
signal
24VDC
0
ACTUAL t
temperature
T2
T1
0
t
T1 = Preheating temperature (PREHEAT)
T2 = Heatsealing temperature
The ACTUAL temperature shows whether the heatsealing band is heated up to the preheating temperature cor-
rectly, providing the display is in the home position.

10.12 Cycle counter
Each activation of the "START" signal during operation is detected by a cycle counter integrated in the controller.
Actuations of the "HAND" key are not counted. The counter reading can be displayed with step 214 [30] in the
Configuration menu.
The cycle counter is reset to 0 if the "ENTER" key is pressed or if the maximum count of 999.999.999 cycles is
exceeded.
10.13 Hold mode
The behavior of the digital indication of the ACTUAL temperature in the home position can be changed with
step 106 [6] in the Settings menu. The following settings are possible:
1. "OFF" (Factory setting)
If the main menu is visible on the display, the real ACTUAL temperature is always indicated.
2. "ON"
If the display is in the home position, the ACTUAL temperature that was valid at the end of the last heatsealing
phase is always indicated as a digital value. When the controller is switched on, the real ACTUAL temperature
is indicated until the end of the first heating phase.
3. "2 s"
It causes the current ACTUAL temperature to be displayed as a digital value for an additional 2 seconds at the
end of a heatsealing phase. This temperature is then indicated again in real time until the end of the next
heating phase.
Hold mode only affects the digital value on the display. The ACTUAL temperature in real time is
! always indicated, regardless of the setting, by the dynamic bar and the actual value output.

The various hold modes are shown below:
START
signal
24VDC
0
ACTUAL t
temp.
T
0
t
ACTUAL indication
Hold OFF
T
0
t
Hold ON Hold Hold
T
0
t
Hold 2 s Hold Hold
T
0
t
2s 2s
End of
heating phase
The word "Hold" appears on the display if a temperature value is indicated in hold mode. It disappears for approx-
imately 100ms whenever the hold value is updated.
10.14 Measuring impulse duration (as of software revision 026)
The length of the measuring impulses generated by the controller can be set with this parameter by means of
step 220 [32]. It may be necessary to set a measuring impulse that is longer than the default 1.7ms for certain
applications ( ROPEX Application Report).

10.15 Automatic phase angle compensation (AUTOCOMP) (as of software

revision 100)
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. It can be parameterized with step 221 as followed:
1. „OFF" (Factory setting)
The „AUTOCOMP“ function is deactivated.
2. „ON“
The „AUTOCOMP“ function is activated by pressing the "ENTER" key after the "AUTOCAL" function has been
successfully executed ( section 10.9 "Automatic zero calibration (AUTOCAL)" on page 53). The interval after
the end of the "AUTOCAL" function must be less than 2.0s ("Start AUTOCOMP? Start with ENTER" appears
on the display during this time). The subsequent "AUTOCOMP" function is executed in approximately 2.0s ("-
AUTOCOMP - Please wait…" appears on the display during this time).
If the interval following the successful execution of the "AUTOCAL" function is longer than 2.0s, the display
returns to the home position and the "AUTOCOMP" function is not executed.
„ENTER“ key <2.0s

pressed
„AC“ „AP“
0
t
Function
AUTOCOMP
AUTOCAL
0
t
The actual value output (terminals 24+23) is set to 0…3°C (i.e. approx. 0 VDC) when the "AUTOCOMP" func-
tion is executed.
3. „AUTO“
With this setting the „AUTOCOMP“ function is activated automatically after the "AUTOCAL" function has been
successfully executed.
„ENTER“ key
pressed
„AC“
0
t
Function
AUTOCOMP
AUTOCAL
0
t

The actual value output (terminals 24+23) is set to 0…3°C (i.e. approx. 0 VDC) when the "AUTOCOMP" func-
tion is executed.
10.16 Locking the "HAND" key (as of software revision 100)
The "HAND" key function can be configured with step 213 in the Configuration meun when the display is in home
position.
This prevents the heatsealing bands from beeing heated if the "HAND" key is pressed inadvertenly.
1. Lock „OFF“ (Factory setting)
Pressing the "HAND" key while the display is in the home position starts amanual heating process. The heat-
sealing band is heated as long as the "HAND" key remains pressed.
2. Lock „ON“
The "HAND" key is locked when the display is in the home position, in other words it has no function.
10.17 Temperature unit Celsius / Fahrenheit (as of software revision 106)
As of software revision 106 the unit for the temperature indication and value selection can be switched between
°C (Celsius) and °F (Fahrenheit). It can be parameterized with step 225 as followed:
1. „Celsius“ (Factory setting)
Temperature indication and value selection in
Celsius (°C).
2. „Fahrenheit“
Temperature indication and value selection in
Fahrenheit (°F)
Up to software revision 105 only Celsius (°C) can be specified on the controller as the temperature unit.
The degree unit can be changed on the controller without interrupting operation
!
If you specify temperature indication and value selection in Fahrenheit (°F), the controller still uses
! Celsius (°C) internally. Value steps are therefore possible with this function owing to the conversion
from Celsius to Fahrenheit.
10.18 Disabling the Configuration menu

It is possible to disable all changes to values/parameters in the Configuration menu. This prevents the controller
configuration from being tampered with by unauthorized persons.
The Configuration menu can be disabled or enabled by pressing the "MENU" key for 2.0seconds while the power-
up message is displayed (after switching on the controller,  section 10.2.1 "Power-up message" on page 35).
The display then shows a message confirming that the disable function is active for 3.0seconds before returning
to the home position.

The same message is also displayed for 5.0seconds when you open the Configuration menu to indicate that this
menu is disabled.
You can still display all steps, values and parameters even if the Configuration menu is disabled.
! You are no longer allowed to enter or change values, however.
As of software revision 103 the language in menu pos. 201 can be changed while the configuration
! menu is locked ( section 9.3.2 "Setting the language" on page 25).
The Configuration menu remains disabled until the disable function is canceled again. To do so, repeat the above
procedure (press the "MENU" key for 2.0seconds while the power-up message is displayed). The display then
shows a message confirming that the disable function has been canceled.
In the factory setting the Configuration menu is not disabled.
10.19 Setting the display brightness (VF display only)

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.
The factory setting is 75%.
The life of the VF display can be prolonged by reducing the brightness.
10.20 Undervoltage detection
Trouble-free operation of the temperature controller is guaranteed within the line voltage tolerance range specified
in section 6 "Technical data" on page 13.

If a line voltage which is less than the lower limit of the permissible range occurs, the controller is switched to a
standby mode. No more heatsealing processes take place and no more measuring impulses are generated. The
display changes to indicate this.
The main menu is displayed again, and operation is resumed, when the input voltage returns to the specified tol-
erance range.
The alarm relay (terminals 5+6) is only switched by an undervoltage condition in controllers up to and including
software revision 008. The last valid temperature value continues to appear at the analog output (terminals
23+24).
The alarm relay in controllers with a higher software revision number is not switched if an undervoltage condition
occurs. The standby mode is indicated by 0…3°C (corresponds to app. 0V) at the analog output.
Trouble-free operation of the controller is only guaranteed within the specified input voltage toler-
! ance range. An external voltage monitor must be connected to prevent defective heatseals as a
result of low line voltage.

10.21 Diagnostic interface/visualization software (as of software revision 100)
An interface with a 6-pole Western socket is provided for systemdiagnostics and process visualization. This inter-
face allows a data connection to be set up to the ROPEX visualization software using the ROPEX communication
interface CI-USB-1.
IR UR 12
DIAG
8 9 10 11
Back view of the controller
Only a ROPEX comunication interface is allowed to be connected to the diagnostic interface. Con-
! necting another device (e.g. a telephone cable) could result in malfunctions or damage to the con-
troller.
The ROPEX visualization software is described in a separate document.
10.22 Booster connection
The RES-440 controller has a connection for an external switching amplifier (booster) as standard. This connec-
tion (at terminals 1+2) is necessary for high primary currents (continuous current > 5A, pulsed current > 25A). The
switching amplifier should be connected as described in section 8.7 "Wiring diagram with booster connection" on
page 22. No settings are required in the menu.

10.23 Time control (timer function)
10.23.1 Activation and indication
The settings described here are only allowed to be entered by technically trained persons. An incor-
! rectly parameterized timer function may cause disruptions to operation and damage to the machine.
The timer function is activated with step 209 [26] in the Configuration menu. There are two possible settings in this
menu:
1. "OFF" (Factory setting)
Time control (timer function) deactivated
2. "ON"
Time control (timer function) activated.
The internal timeout is started by activating the "START" signal. The timeout either ends with the parameterized
cooling phase or is interrupted by activating the "RESET" signal.
3. "ON with START monitoring"
Time control (timer function) activated and "START" signal monitored.
Once again, the internal timeout is started by activating the "START" signal. In this setting, however, the
"START" signal must remain activated until the end of the parameterized cooling phase. If the "START" signal
is deactivated before the end of the cooling phase - or if the "RESET" signal is activated - the timeout is inter-
rupted.
If time control is on, activating the "START" signal starts the internally parameterized timeout. This timeout com-
prises:
• Starting delay (delay at the beginning of the heating phase)
• Heating phase (heating and control process)
• Cooling phase
• Relay K1 function

If time control (timer function) is activated, it is only possible to start a heating process with the
! "HAND" key on the controller. The timeout of the internal time control cannot be started with this
key.
START
signal
24VDC
0
ACTUAL t
temp.
T
0
Relay K1 t
(example)
closed
0
t1 t2 t3 t
t1 = Starting delay
t2 = Heating phase
t3 = Cooling phase
The timeout of the internal time control (timer function) can be interrupted by switching off the con-
! troller. As of software revision 021, it can also be interrupted by deactivating the "START" signal if
time control "ON with START monitoring" is configured.
If the display is in the home position, the individual timeouts can be monitored there.
The remaining heatsealing time is indicated on the display in the form of a countdown at the end of the heating
phase. A direction arrow indicates the active process.
The active cooling phase is subsequently marked with the direction arrow at the end of the heating phase.
The direction arrow disappears again at the end of the cooling phase (i.e. at the end of the internal timeout).

The current condition of relay K1 is indicated by means of a separate icon. If the icon is visible, the normally open
contact of the relay is closed.
Separate settings can be entered for the individual timeouts. These settings are possible with steps 103 [3],
104 [4] and 105 [5] in the Settings menu and with steps 210 [27], 211 [28] and 212 [29] in the Configuration menu.
The options available with these advanced settings are described below.
10.23.2 Setting the starting delay

The start of the heating process can be explicitly delayed by entering a starting delay time with step 103 [3] in the
Settings menu, e.g. in order to bridge the closing time of the heatsealing bars.
When the "START" signal is activated, the controller waits for the time specified with this menu step to elapse
before commencing the heating process.
START
signal
24VDC
0
ACTUAL t
temp.
T
0
t1 t
t1 = Starting delay
The starting delay can be set in the range from 0 to 9.9s. A delay of 0s is defined as the factory setting. In this
case, the heating process begins as soon as the "START" signal is activated.
10.23.3 Setting the heatsealing time

This menu step is used to enter the heatsealing time. There are two possible ways to set the heatsealing time:
1. "0…99.9s"
The heatsealing time can be set in the range from 0 to 99.9s. The factory setting is 1.0s.
2. "EXT"
(This setting is possible as of software revision 013)
The heatsealing time is controlled by the "START" signal (24VDC signal applied to terminals 3+4 or contact

applied to terminals 2+7). The duration of the heatsealing time is equal to the active time of the "START" signal.
START
signal
24VDC
0
ACTUAL t
temp.
T
0
t2 t
t2 = Heating phase
10.23.4 Setting the cooling mode

Various criteria for the end of the cooling phase can be specified with step 210 [27] in the Configuration menu of
the RES-440 controller. The possible settings are as follows:
1. "Absolute" (Factory setting)
The cooling phase ends when the ACTUAL temperature of the heatsealing band falls below a specified tem-
perature value. This cooling temperature can be set with step 105 [5] in the Settings menu.
2. "Relative"
The cooling phase ends when the ACTUAL temperature falls to a value corresponding to X% of the SET tem-
perature. This percentage cooling value can be set with step 105 [5] in the Settings menu.
Example:
SET temperature = 180°C, cooling value = 60%
 Cooling phase ends when ACTUAL temperature ≤ 108°C
3. "Time"
The cooling phase ends after a specified time in seconds and is independent of the ACTUAL temperature. This
cooling time can be set with step 105 [5] in the Settings menu.

The various cooling modes are shown below:
START
signal
24VDC
0
ACTUAL t
temp.
T
0
t
Cooling mode
T t3 = Cooling phase in °C
Absolute T
2
0
t3 t
T t3 = Cooling phase as
Relative % of set point
X%
0
t3 t
T t3 = Cooling phase in s.
Time
0
t3 t
10.23.5 Setting the cooling value

After the cooling phase has been configured with step 27 in the Configuration menu ( section 10.23.4 "Setting
the cooling mode" on page 67), you can specify the cooling parameters with step 105 [5] in the Settings menu.
The options available with step 105 [5] in the Settings menu vary according to the selection made
! with step 210 [27] in the Configuration menu. All settings entered with menu step 105 [5] are over-
written if step 210 [27] is changed subsequently.
The possible settings are as follows:

1. "Cooling temp. in °C"
(if setting with menu step 210 [27] = "Absolute")
The cooling phase of the internal timeout ends when the ACTUAL temperature of the heatsealing band falls
below the set temperature.
The minimum settable temperature is 50°C. This is also the factory setting.
The maximum value of the setting range is limited either by the maximum value specified with
! step 206 [23] in the Configuration menu or by the heatsealing band type/temperature range set with
step 205 [22].

2. "Cooling temp. in %"

(if setting with menu step 210 [27] = "Relative")
The cooling phase of the internal timeout ends when the ACTUAL temperature falls to the specified percentage
of the SET temperature. This value can be set between 40 and 100%.
The factory setting is 40%.
3. "Cooling time in s"
(if setting with menu step 210 [27] = "Time")
The cooling phase ends when the specified time elapses. This time can be set between 0 and 99.9s.
The factory setting is 10.0s.
10.23.6 Setting the start of the heatsealing time

The condition for the start of the set heatsealing time (step 104 [4] in the Settings menu) can be specified with
step 211 [28] in the Configuration menu. The following settings are possible:
1. "When heating starts"
The parameterized heatsealing time starts as soon as the set starting delay elapses ( Settings menu,
step 103 [3]).
If the starting delay = 0s, the heatsealing time begins as soon as the "START" signal is activated.
2. "When temperature reached" (Factory setting)
Once again, the heating process starts as soon as the set starting delay elapses ( Settings menu,
step 103 [3]). The specified heatsealing time does not start, however, until the ACTUAL temperature of the
heatsealing band reaches 95% of the SET temperature.
These two alternatives are shown below:
START
signal
24VDC
0
ACTUAL t
temp. 95% of set point
T
0
t
Start of
heatsealing time
When
heating
starts
Heatsealing time
0
When t
temperature
reached
Heatsealing time
0
t

10.23.7 Relay K1 (with time control)

The function of relay K1 when time control is active is also specified with step 212 [29] in the Configuration menu
( section 9.3.8 "Relay K1 (without time control)" on page 27). The settings described here are only possible if
time control is active. These settings can be selected as follows:
1. „OFF“
Relay K1 without function
2. "When start signal present"
The normally open contact of relay K1 closes as soon as the "START" signal is activated and remains closed
until the end of the parameterized timeout (i.e. until the end of the cooling phase).
3. "When temperature reached" (Factory setting)
The normally open contact of relay K1 closes when the ACTUAL temperature reaches 95% of the SET tem-
perature and remains closed until the end of the parameterized timeout (i.e. until the end of the cooling phase).
4. "While cooling" (Software revision 010 or higher)
The normally open contact of relay K1 closes at the end of the heating phase and opens again at the end of
the cooling phase.
This configuration permits air cooling to be activated with relay K1 during the cooling phase, for instance.
5. "End-of-cycle impulse"
The normally open contact of relay K1 closes at the end of the parameterized timeout (i.e. at the end of the
cooling phase) and opens again after approximately 500ms. If a "START" signal is activated while relay K1 is
still closed, the relay opens again immediately.

The possible settings are shown below:
START
signal
24VDC
0
ACTUAL t
temperature 95% of set point
T
end of cooling
0
t
Relay K1
When start
signal present
0
When t
temperature
reached
0
t
While
cooling
0
t
End-of-
cycle 500ms
impulse
0
t

6. "Active if Tact = Tset" (This setting is possible as of software revision 100)

Relay K1 is activated if the actual value is inside the specified temperature tolerance band (steps 207, 208). If
the actual temperature is outside the tolerance band, relay K1 is deactivated (see graph below).
Actual value
Set+ Δϑ upper
Set
Setl+ Δϑ lower
Time
NO contact of
Relay K1
Closed
Open
Time
7. "Active if Tact = Tset", with latch function (This setting is possible as of software revision 100)
Relay K1 is closed if the actual value is inside the specified temperature tolerance band (steps 207, 208). If the
actual temperature leaves the tolerance band once during the heatsealing phase, relay K1 is opened. The relay
is not closed again until the next "START" signal is activated. The switching state of relay K1 can thus also be
interrogated by the higher-level PLC after a heatsealing process (latch function, see graph below).
Actual value
Set+ Δϑ upper
Set
Set+ Δϑ lower
Time
NO contact of
Relay K1
Closed
Open
Time
10.23.8 “Output 1“/ “Temperature OK“ signal (with time control)
On controllers up to software revision 027, the switching output at terminals 20+21 was called
! "Temperature OK". The more general name "Output 1" is used as of software revision 100 because
this output now also supports other functions.

The "Output 1" signal is available at terminals 20+21 as a digital control signal.
+24VDC
RES-440
21
Imax 50mA
20
GND
GND

The switching output at terminals 20+21 ("Temperature OK" signal) always has the function "Active if Tact = Tset"
( section 9.3.9 "“Output 1“/ “Temperature OK“ signal (without time control)" on page 28).

If time control (timer function) is active, the switching output at terminals 20+21 ("Output 1") can be parameterized
in the same way as relay K1. The options for "Output 1" are specified with step 222 in the Configuration menu as
followed:
1. "Off"
2. "When start signal present"
3. "When temperature reached"
4. "While cooling"
5. "End-of-cycle impulse"
(factory setting)
For a detailed description of these functions, see section 10.23.7 "Relay K1 (with time control)" on page 70.
10.23.9 Preheating (with time control)

If time control is active, the preheating temperature ( section 10.11 ""PREHEAT" signal (preheating)" on page 55
is only deactivated during the heating phase. Preheating is active during the starting delay and the cooling phase.
The ACTUAL temperature consequently cannot fall below the set preheating temperature during the cooling
phase.
The temperature which is set for the end of the cooling phase ( section 10.23.5 "Setting the cooling value" on
page 68) must always be higher than the preheating temperature. If not, the end of the cooling phase is never
reached, i.e. the internal timeout does not elapse.
If the cooling temperature is required to be lower than the preheating temperature, the "PREHEAT" signal must
be deactivated until the end of the cooling phase and then activated again.

10.23.10Example
The example below illustrates the basic design of a pneumatically operated L-sealer with a solenoid valve. The
heatsealing process is started by means of a foot switch.
U Solenoid valve
Cylinder
Controller Relay K1
Heatsealing bar
Heatsealing band
Film
Film
Retainer
Start
Foot contact
The functional sequence is as follows:

1. The controller receives the "START" signal for internal time control via the foot switch.
2. The heating process must begin immediately – without a starting delay.
3. When the ACTUAL temperature reaches 95% of the SET temperature (T = 180°C), the normally open contact
of relay K1 must close. The solenoid valve is then energized and the sealing jaws are closed.
The heatsealing time (t2 = 1s) begins simultaneously.
4. The heatsealing bands are not heated any further at the end of the heatsealing phase (i.e. at the end of the
heatsealing time). The cooling phase begins.
5. The cooling phase must end when the ACTUAL temperature of the heatsealing bands falls to T ≤ 80°C. The
sealing jaws are still closed (the normally open contact of relay K1 is also still closed).
6. The normally open contact of relay K1 opens again at the end of the cooling phase. The sealing jaws are also
opened again.
7. End of the heatsealing process.

The timing sequence can be represented as follows:
START signal (foot switch)
0
ACT temperature t
95% of 180°C
180°C
80°C
0
t
NO contact of 1s
relay K1
Closed
Open
t
Required controller settings:
The following controller settings are required for time control (the basic settings such as the temperature range,
alloy etc. should already have been entered).
The settings should be undertaken in the specified order.
Step in Configuration menu Setting
26 (Time control) "ON"
27 (Cooling mode) "Absolute"
28 (Start of heatsealing time) "When temp.

reached"
29 (Relay K1 function) "When temp.

reached"
Then:
Step in Settings menu Setting
101 [1] (Heatsealing temp.) 180°C
103 [3] (Starting delay) 0.0 s
104 [4] (Heatsealing time) 1.0 s
105 [5] (Cooling value) Cooling

temp. = 80°C

10.24 System monitoring/alarm output
To increase operating safety and to avoid faulty heatsealing, the controller incorporates special hardware and soft-
ware 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.
A.) Error message on the display:
The cause of a fault can be localized quickly and easily with the help of the error code that appears on the display.
Please refer to section 10.26 "Fault areas and causes" on page 81 for a list of the possible error codes.
B.) Alarm relay (relay contact, terminals 5+6):
This contact is set in the factory as follows:

• OPEN if error code 104…106, 111…113 or 211 is displayed. The contact closes, however, if a "START" signal
is activated in this state.
• CLOSED if error code 101…103, 107, 108, 201…203, 801 or 9xx appears.
If the alarm relay is configured differently from the factory setting ( section 9.3.12 "Configuration of the alarm
relay" on page 31), these states are inverted.
C.) Error code output via the 0 to 10VDC actual value output (terminals 23+24):
Since a temperature indication is no longer necessary if a fault occurs, the actual value output is used to display
error codes in the event of a fault.
13 voltage levels (up to software revision 027: 12 voltage levels) are offered for this purpose in the 0…10VDC
range, each of which is assigned an error code ( section 10.26 "Fault areas and causes" on page 81).
If a state that requires AUTOCAL occurs – or if the controller configuration is incorrect – (error codes 104…106,
111…113 or 211), the actual value output jumps back and forth at 1Hz between the voltage value that 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 error message can only be reset by pressing the "RESET" key or 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.

10.25 Error messages
The table below shows how the analog voltage values that appear at the actual value output correspond to the
faults that have occurred. It also describes each fault and the required corrective action. The block diagram in
section 10.26 "Fault areas and causes" on page 81 permits each fault to be cleared quickly and efficiently
The error codes described below can also be displayed in the ROPEX visualization software ( section 10.21
"Diagnostic interface/visualization software (as of software revision 100)" on page 63) 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 6 "Technical data" on
page 13).

Part 1 of 3:
Page 78
Act. value Temp. Temp. STATUS Action Action if machine
Error
output; 300°C 500°C of alarm relay Cause if machine started already operating,
code
Voltage [V] [°C] [°C] (factory set.) for first time HS band not chang.
1 101 0,66 20 33 IR signal missing Fault area  Fault area 
2 102 1,33 40 66 UR signal missing Fault area  Fault area 
3 103 2,00 60 100 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 2,66 80 133

308 Temperature too low/high
309 Closed ( section 9.3.10)
RES-440
310
201
Frequency fluctuation, Check
5 202 3,33 100 166 Check power supply
inadmissible line frequency power supply
203
Heatup time too long
6 304 4,00 120 200 Run RESET Run RESET
( section 9.3.11)
901 Int. faut, contr. defective Replace controller Replace controller

913 Triac defective Replace controller Replace controller
7 914 4,66 140 233 Int. faut, contr. defective Replace controller Replace controller
Version 1
Part 2 of 3:
Version 1
NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;
alarm relay is open). 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 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 
UR and/or IR signals
5,33 160 266 incorrect, Fault area 
RES-440
8 106 Fault:
 10  300 500 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
6,00 180 300
9 211 Data error Run AUTOCAL ---
 10  300 500
Page 79
Part 3 of 3:
Page 80
NOTE: The specified error messages are initially output as warnings (actual value output jumps back and forth between two values;
alarm relay is open). 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 relay is closed).

Error
code
6,66 200 333 IR signal incorrect, Fault area ,

10 111 ---
 10  300 500 calibration not possible check configuration
Warning:
7,33 220 366 UR signal incorrect, Fault area ,
11 112 Open ---
8,00 240 400 UR and IR signals incorrect, Fault area ,
12 113 Fault: ---
Closed
(voltage value Temperature fluctuates,
114
at actual calibration not possible
value output
RES-440
8,66 260 433 Ext. calibration
13 115 then no longer
 10  300 500 temperature too high,
changes)
Ext. calibration
116
temperature fluctuates
Version 1
10.26 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 heat-

 Total short-circuit sealing 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

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)

Factory settings
11 Factory settings
The RESISTRON® temperature controller RES-440 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 AUTO-
RANGE function on all controllers as of software
revision 100.
Settings menu No. 101 [1] Heatsealing temperature: 0°C

No. 102 [2] Preheating temperature: 0°C
No. 103 [3] Starting delay: 0s
No. 104 [4] Heatsealing time: 1s
No. 105 [5] Cooling value: Cooling time: 10 s
Absolute cooling temperature: 50°C
Relative cooling temperature:
40 % of heatsealing temperature
No. 106 [6] Hold mode: OFF
No. 107 [7] 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 A20/max. 300°C
No. 206 [23] Maximum temperature: 300°C
No. 207 [24] Set point reached: -10K
No. 208 [25] Set point exceeded: +10K
No. 209 [26] Time control: OFF
No. 210 [27] Cooling mode: Absolute
No. 211 [28] Start of heatsealing time: When temperature reached
No. 212 [29] Relay K1 function: Active when temperature reached
No. 213 Lock of „HAND“ key OFF
No. 214 [30] Cycle counter: 0
No. 215 [31] Alarm relay: Normal (contact closed by a fault)
No. 216 [33] Analog output: Actual temperature
No. 217 Temperature diagnosis: OFF
No. 218 Temp.diagnosis
delay time: 0s
No. 219 Heatup timeout: OFF
No. 220 [32] Measuring impulse length:Standard (1.7ms)
No. 221 Autocomp: OFF
No. 222 "Output 1": Active if Tact = Tset, with latch function
No. 225 Temperature unit: Celsius

Factory settings
The controller can be reset with step 21 in the Configuration menu:
The factory settings are restored if the "ENTER" key is pressed. An acknowledgment message is displayed for
approximately 2s.
The language which is selected with step 20 in the Configuration menu remains set even if the fac-
! tory settings are restored.

Maintenance
11.1 Customer settings (as of software revision 100)
The controller factory settings can be specified or restored with step 202 in the Configuration menu. You can also
store customer settings in addition to the Ropex settings:

1. „Restore Ropex settings“ (Factory setting)
Selecting this option restores the menu values listed in section 11 "Factory settings" on page 83. 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 currently set in the controller Settings and Configuration menus
as "customer settings". These "customer settings" are independent of the Ropex settings. Machine-specific
settings can be stored in the controller in this way.
3. „Restore customer settings
Selecting this option restores the "customer settings" that were saved as described in 2.
When the controller is first delivered, the "customer settings" are identical to the Ropex settings.
!
After pressing the "ENTER" key in this menu step, you are asked to confirm the new settings (safety query).
Another message appears if you now confirm these settings by pressing the "ENTER" key for approximately
2seconds.
You can also cancel the new settings by pressing the "MENU", cursor "UP" or cursor "DOWN" keys. Step 203 then
appears on the display.
The language which is selected with step 201 in the Configuration menu remains set even if the pre-
! vious settings are restored.
12 Maintenance
The controller requires no special maintenance. Regular inspection and/or tightening of the terminals – including
the terminals for the winding connections on the impulse transformer – is recommended. Dust deposits on the con-
troller can be removed with dry compressed air.

How to order
13 How to order
Contr. RES - 440- . / . . . VAC
L / 115: LC display, line voltage 115VAC, Art. No. 744011
V / 115: VF display, line voltage 115VAC, Art. No. 744021
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-440-L/400VAC + MOD 01
(controller with LC display for 400VAC line voltage
and amplifier for low voltage)
Art. Nos. 744013 + 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
Temp. meter ATR- .

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

How to order
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

Index
14 Index
A Fault diagnosis 10, 76
Accessories 10 Front cover 11
Actual value output 51 Fuse 18
Adapter for top hat rail mounting 11
Additional relay K1 14 H
Alarm output 76 HEAT 34, 54
Alarm relay 14, 31 Heatsealing band type 13
Alloy 25, 26, 34 Heatsealing time 66
Ambient temperature 14 Heatup timeout 31
Analog temperature meter 10 Hold mode 57
Application 8
Application Report 16, 19, 24
I
AUTOCAL 9, 33, 53
Impulse heatsealing method 8
AUTOCOMP 59
Impulse transformer 10, 18, 86
Automatic phase angle compensation 59
Installation 14, 16
Automatic zero calibration 9, 33, 53
Installation procedure 16
AUTOTUNE 9
Installation regulations 16
B L
Booster 11, 22, 87
Line filter 5, 10, 18, 19, 86
Booster connection 63
Line frequency 9, 13
Burning in heatsealing band 32, 34
Line voltage 13
Locking the "HAND" key 60
C
Celsius °C 60
M
Circuit-breaker 18
Maintenance 5, 85
CI-USB-1 11, 63, 86
Manual mode 50
Communication interface 11, 63, 86
Measurement cable 11
Controller configuration 24
Measuring impulse duration 58
Controls 35
Modifications 11, 86
Current transformer 11, 19, 86
MODs 11, 86
Customer settings 85
Monitoring current transformer 11
Cycle counter 57
O
D
Output 1 14, 28, 72
Degree of protection 14
Over-current protection 18
Diagnostic interface 63
Overheating of heatsealing band 9
Digital temperature meter 10
Dimensions 15
DIP switches 24 P
Disabling Configuration menu 60 PEX-W3 86
Display 35 PEX-W4/-W5 5, 19
Display brightness 61 Phase angle compensation 59
Disposal 6 Power dissipation 14
Power supply 18
Preheat 55
E
"PREHEAT" signal 55
Error messages 77
Principle of operation 8
External switching amplifier 11, 22
R
F
Relay K1 27, 70
Factory settings 25, 83
Replacing heatsealing band 32, 34
Fahrenheit °F 60
Fault areas 81

Index
S Temperature setting 50
Sealing time 66 Temperature unit 60
Secondary current I2 24 Time control 27
Secondary voltage U2 24 Timer function 27, 54
Set point selection 13, 50 Transformer 5, 10, 18, 86
Standby mode 62 Transportation 5
"START" signal 34, 54 Type of construction 13
System diagnostics 63
System monitoring 76 U
Undervoltage detection 61
T
TCR 4, 31 V
Temperature coefficient 4, 26, 31 View of controller 23
Temperature control 8 Visualization software 63
Temperature diagnosis 30
Temperature indication 51
W
Temperature meter 10, 52, 86
Wiring 16, 18
Temperature OK 14
Wiring diagram 21, 22
Temperature OK signal 14
Temperature range 13, 25, 27

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RESISTRON

• Alarm function with fault diagnosis

Identical design to and compatible with RES-222, -230, -241, -242

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

8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . 16 10.15 Automatic phase angle compensation

Page 2 RES-440 Version 1

Version 1 RES-440 Page 3

1.2 Intended use

1.3 Heatsealing band

Page 4 RES-440 Version 1

1.4 Impulse transformer

1.5 Current transformer PEX-W4/-W5

1.6 Line filter

Store and transport the device in its original carton.

Version 1 RES-440 Page 5

This device must not be disposed of as residual waste!

Page 6 RES-440 Version 1

Designation: RESISTRON temperature controller with accessories

Type: RES-440 with line filter and current transformer

Operating principle: Impulse sealing of films and plastics

Compliant with following standards and directives:

2014/35/EU low voltage directive

2014/30/EU electromagnetic compatibility directive

2011/65/EU RoHS directive

July 12, 2020

ROPEX Industrie-Elektronik GmbH

Version 1 RES-440 Page 7

Page 8 RES-440 Version 1

Heatsealing band R = f (T)

4 Description of the controller

Version 1 RES-440 Page 9

5 Accessories and modifications

Analog temperature meter ATR-x

Digital temperature meter DTR-x

Line filter LF-xx480

Impulse transformer ITR-x

Page 10 RES-440 Version 1

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)

Version 1 RES-440 Page 11

Page 12 RES-440 Version 1

Line voltage All controller manufactured as of March 2006

All controllers manufactured as of January 2004 up to February 2006

All controllers manufactured up to December 2003:

depending on device version ( section 13 "How to order" on page 86)

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

Analog output 0…10VDC, Imax = 5mA

Version 1 RES-440 Page 13

Digital logic levels LOW (0V): 0…2VDC

Switching output Umax = 30VDC, Imax = 50mA

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

Relay K1 Changeover contact, potential-free, Umax = 240VAC/100VDC, Imax = 1.5A