3ES080x_V5_1_MU_EN

TEMPERATURE CONTROLLER FOR IMPULSE SEALING
THERMOSALD
ISC
MODULAR SYSTEM
• AUTOMATIC CALIBRATION
• ANALISYS ON LINE OF BAND CHARACTERISTICS
•
• DIAGNOSTIC PANEL WITH 6 LANGUAGES
• SET UP OF SEALING BAND PPM CHARACTERISTIC
•
• RS 485 INTERFACE (OPTIONAL)
• WORKING WITH POTENTIOMETER
•
• BURN IN OF SEALING BAND
MAINTENANCE & OPERATIONS MANUAL

(V5.1)
3E S.r.l. - Via del Maccabreccia 37/a - 40012 LIPPO DI CALDERARA ( BOLOGNA )
Tel. ++39 051 6466225-228 e-Mail: mail@3e3e3e.com
Fax ++39 051 6426252 web site: www.3e3e3e.com
CONTENTS
0 WARNINGS
0.1 SAFETY PRECAUTIONS
0.2 COMPLIANCE WITH ELECTRO-MAGNETIC STANDARD
1 DESCRIPTION
1.1 DESCRIPTION OF MANUALS
1.2 GENERAL DESCRIPTION
2 WIRING DIAGRAM AND DIMENSIONS
2.1 LIST OF CHANGE-OVER SIGNALS
2.2 WIRING DIAGRAMS
3 INSTALLATION
3.1 ANALYSIS OF APPLICATION
3.2 CALCULATION OF SEALING BAND RESISTANCE
3.3 THERMOREGULATOR CHOISE
3.4 POWER TRANSFORMER CHOISE
3.5 PROTECTIVE DEVICE CHOISE
3.6 ADVICES TO DEVELOP ELECTRIC CONNECTIONS
4 START UP
4.1 START UP – GENERAL OPERATIONS
4.2 START UP – BASE CONFIGURATION
4.3 START UP – BASE + MULTILANGUAGE PANEL
4.4 START UP – BASE + BASE + MULTILANGUAGE PANEL + POTENTIOMETER
4.5 START UP – BASE + CAN BUS
4.6 START UP – BASE + PROFIBUS
4.7 INSTRUCTION TO USE MULTILANGUAGE PANEL
4.8 THEORETICAL CALCULATIONS AND DIAGNOSTIC PROCEDURES WITH THE AID OF THE
DATA IMPUT PANEL
4.9 SETUP PROCEDURES WITH THE AID OF THE CONTROL PANEL
4.10 SETUP PROCEDURES WITHOUT USING THE CONTROL PANEL – MANUAL MODE
5 MAINTENANCE
5.1 CHANGING THE SEALING BAND WITH MACHINE COLD
5.2 CHANGING THE SEALING BAND WITH MACHINE HOT
5.3 TROUBLESHOOTING
5.4 THERMOREGULATOR MAINTENANCE
5.5 GRIPPER JAWS MAINTENANCE
6 SPECIFICATIONS
6.1 SPECIFICATIONS
7 DETAILS FOR ORDER FORM
7.1 DETAILS FOR ORDER FORM
App. A TYPICAL SEALING CYCLE
App. B MACHINE DATA LIST
App. C SETTING DATA LIST
App. D FAULT AND WARNING LIST ( CAUSES - REMEDIES )
App. E DIMENSIONS
App. F TRANSFORMER TECHNICAL FEATURES
App. G START UP CARD
THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

(Includes all previous models)
Manuale cod.: 3ES080x_V5.1_MU_EN Page Nr. 2 Tot. Nr . 47
0 WARNINGS
THIS BOOK IS SUPPLIED WITH OUR PRODUCT AND DESCRIBES THE FUNDAMENTAL FUNCTIONS
EMPLOY QUALIFIED AND WELL-TRAINED PERSONNEL, FAMILIAR WITH THE TECHNOLOGY USED
TO INSTALL OR MAINTENANCE THE EQUIPMENT, CONSULTING MAINTENANCE & OPERATIONS
MANUAL.
0.1 SAFETY PRECAUTIONS
- Never use the equipment in explosive atmospheres or with explosive materials.

- Never use the equipment with flammable material without first taking the required
safety precautions.
- Operate the equipment by following the instructions contained in this
MAINTENANCE & OPERATIONS MANUAL before doing an installation.
- Never turn on the temperature controller power circuit when the safety guards are
open.
- Do not use the temperature controller for tasks other than those it is designed for i.e
to control the temperature of bands or wires for industrial-grade sealing. Contact our
engineering department for information regarding specific applications.
- Do not deliver electrical power to the temperature controller if the protective cover
has been removed for special servicing on the electronic system.
- Employ qualified and well-trained personnel familiar with the technology used, to
install and use the equipment.
- Grounding the thermoregulator by yellow-green cable connected to the predisposed
screw and by 4 fixing screw.
- Use bands or wires having an adequate positive temperature coefficient >900 PPM (
900 part per million, > 900 x 10E-6)
- When the machine is running under normal conditions, make sure the heat sink of
the controller does not exceed 60°C . If this happens, increase heat sink ventilation
or contact our engineering department.
- When the sealing bands are in parallel pay attention at the connections of the cables
that must not be crossed; with the correct connection the current flow in both sealing
bands in the same direction and all the points opposite of the sealing bands have the
same voltage and in the case of an accidental contact it is not possible having a short
circuit between sealing bands and a high current. Viceversa if the sealing bands
touch ground, possible case, the thermoregulator blocks up the current immediately.

0.2. COMPLIANCE WITH ELECTRO-MAGNETIC STANDARDS – CE KITE MARKS
TESTS AND RESULTS:
Test conditions:
• Mains supply filter Mod. Siemens B84112-B-B60 ( 115 / 250 V - 6A - 50/60 Hz )
• Connecting cable thermoregulator-panel mt.5
• Input power cables length mt. 5
• Output power cables length mt.5
Normative References:
• CEI EN 50081-2 (06/1997) Electromagnetic compatibility – Generic emission standard - Part 2 - industrial
environment.
• CEI EN 61000-6-2 (02/2000) Electromagnetic compatibility - Generic immunity standard - industrial environment.
EMISSION Requisites
Test Normative References Test Result
• Electromagnetic Emission CEI EN 55011 S
IMMUNITY Requisites
• Immunity elecricity static discharge (ESD) CEI IEC 1000-4-2 S
• Immunity radiated electromagnetic field (AM) EN 61000-4-3 S
• Immunity fast transient oscillation (BURST) CEI IEC 1000-4-4 S
• Immunity high energy pulse (SURGE) CEI EN61000-4-5 S
• Immunity conduit RF CEI EN61000-4-6 S
• Immunity electromagnetic field 50Hz CEI EN61000-4-8 S
• Immunity micro interruption of main CEI EN61000-4-11 S
S=Prova Superata
THE PRODUCT IS COMPLIANCE TO ABOVE MENTIONED NORMES EMC in accord to DIRECTIVE

89/336/CEE and DLg N.476/92 e N.615/96
(EMC Test Report n. 029-03-RP on 03/02/03) .
THE PRODUCT IS COMPLIANCE TO LOW VOLTAGE NORME in accord to DIRECTIVE 73/23/CEE,

93/68CEE.

1 DESCRIPTION
1.1 – DESCRIPTION OF MANUALS
In Italian Language (IT) and in English Language (EN) the following manuals are avaliable:
- MANUAL COD. 3ES080x_Vx_CO_IT - COMMERCIAL CATALOGUE: IT DESCRIBES THE PRODUCT AND
ITS FOUNDAMENTAL CARACTERISTICS.
- MANUAL COD. 3ES080x_Vx_QS_IT - QUICK START MANUAL: IT’S SUPPLIED WITH THE
THERMOREGULATOR AND DESCRIBES THE ELETTRICAL CONNECTIONS, THE START UP OPERATIONS,
THE USE OPERATIONS, THE MAINTENANCE OPERATIONS, THE TROUBLE-SHOOTING DIAGNOSTIC.
- MANUAL COD. 3ES080x_Vx_MU_IT – MAINTENANCE & OPERATIONS MANUAL: IT CONTAINS ALL THE
INFORMATIONS ABOUT THE PRODUCT AND MUST BE KNOWN BEFORE DOING AN INSTALLATION; IT’S
SUPPLIED TO INSTALLATOR AND DESCRIBES THE NORMES USED FOR DESIGN, THE INSTAL CONDITIONS
FOR SAFETY, THE ELETTRICAL CONNECTIONS, THE START UP OPERATIONS, THE USE OPERATIONS, THE
MAINTENANCE OPERATIONS, THE TROUBLE-SHOOTING DIAGNOSTIC.
- MANUAL COD. 3ES080x_Vx_CO_EN - COMMERCIAL CATALOGUE

- MANUAL COD. 3ES080x_Vx_QS_EN - QUICK START MANUAL
- MANUAL COD. 3ES080x_Vx_MU_EN - MAINTENANCE & OPERATIONS MANUAL
In French Language (FR), German (DE), Spanish (SP) the following manuals are avaliable:
- MANUALE COD. 3ES080x_Vx_QS_FR - QUICK START MANUAL

- MANUALE COD. 3ES080x_Vx_QS_DE - QUICK START MANUAL
- MANUALE COD. 3ES080x_Vx_QS_SP - QUICK START MANUAL
If requested It will be possible to edit specific language.
ALL MANUALS ARE AVALIABLE ON OUR INTERNET WEB SITE:
www.3e3e3e.com

1.2 GENERAL PRODUCT DESCRIPTION
• APPLICATION: Impulse heat-seal technology is used to seal, rapidly and with great accuracy, polyethylen films,
polyprophilene films, single-component plastic films, multilayer plastic films in general, that must reach their melting
temperature and a cool down immediately to avoid deformations.
• OPERATING PRINCIPLES: To execute impulse sealing, use a sealing bar with a sealing band o wire electrically
insulated from earth, supplied by an equipment specific for impulse sealing, i.e. an impulse thermoregulator. This
equipment must supply the power required to heat the band at the desired sealing temperature in an extremely short time
and maintain the desired temperature with high precision during all the sealing operations; No additional probe are
required, the equipment simpy reads the feedback signals from the bands and controls the heating current with a closed-
loop circuit. The termoregulator first receives a pre-heat signal from the outside so that the sealing bar can reach a
required pre-heat temperature not far from sealing temperature before starting works. The thermoregulator further
receive a sealing signal from the outside so that the sealing bars can reach the correct sealing temperature when brought
together.
• MAIN FEATURES: The thermoregulator THERMOSALD ISC is manufactured in 3 versions: switch of the power
transformer on the secondary up to 60 or 90 ampere, switch on the primary up to 300 Ampere; it’s interchangable with
all the previous thermoregulator by our company; it’s very easy to use.
• RS485 SERIAL INTERFACE: The low cost option /RS485 let user to interface thermoregulator with PLC or PC with
or without digital panel; in this way it’s possible to exchange RUN TIME data, SETTING data and MACHINE data;
with an external temperature probe connected to PLC, it’s possible read temperature of the bar and calibrating the
machine with a very high precision
• EASY TO USE: At start up a calibrating command, automatically calibrate (for sealing bands from 10 cm length to
400)
IMPORTANT
• START UP SUPPORT: The thermoregulator has a special software to dimension the plant: the user introduces bands
characteristics and the thermoregulator display the optimum voltage and power of transformer (see field diagnostic).
• FIELD DIAGNOSTIC: The thermoregulator has a potent diagnostic to compare easily and immediately, the current ,
voltage, resistance, power read in real time with the same memorized during start up and the same calculated theorically
(see start up support): in this way the thermoregulator can enhance the differences which can causes the trouble.
• ALARM DIAGNOSTICS: The temperature controller comes with an efficient diagnostics system capable of
identifying faults which have occured during the production process, indicating the cause and suggesting the remedies
required to restore normal operating conditions.
UPDATE SOFTWARE
• SET SEALING TEMPERATURE IN THE MAIN PAGE (from V5.0): Select setting data “SET TEMPER.PAG1”
=1; in this way temperature can be changed directly pressing the key DOWN ARROW, UP ARROW.
• SET SEALING BAND CHARACTERISTIC (from V5.1): Select TEMPERATURE COEFFICIENT of the sealing
bands in part per milion by the machine data “COEFF.TEMP(PPM).

2 WIRING DIAGRAM AND DIMENSIONS
2.1 LIST OF CHANGE-OVER SIGNALS
CN1 POWER TERMINAL BLOCK (SWITCH ON SECONDARY)

PIN1 ALTERNATING CURRENT SUPPLY (4 - 10 sq.mm)
PIN2 ALTERNATING CURRENT SUPPLY (4 - 10 sq.mm)
PIN3 BAND - (4 - 10 sq.mm)
PIN4 BAND + (4 - 10 sq.mm)
NOTE 1: Power supply and control circuit supply with the same phase
NOTE 2: Twist power cable
CN1 POWER TERMINAL BLOCK (SWITCH ON PRIMARY)

PIN1 ALTERNATING CURRENT SUPPLY (230Vac) (4 - 10 sq.mm)
PIN2 (4 - 10 sq.mm)
PIN3 CONNECT TO 0 VOLTS ON THE SECONDARY OF THE POWER TRANSFORMER (4 - 10
sq.mm)
TO CONTROL LEAKAGE CURRENT TO GROUND
PIN4 ALTERNATING CURRENT SUPPLY (230Vac) (4 - 10 sq.mm)
NOTE 2: Twist power cable
CN2 CONTROL CIRCUIT SUPPLY TERMINAL BLOCK

PIN 1 400 Vac ( 0.1A absorption, max) (1sq.mm)
CN3 CONTROLS TERMINAL BLOCK

PIN1 COMMON 0 V PLC (24V DC) (1 sq.mm)
PIN2 IN PRE-HEAT SIGNAL FROM PLC, 24V DC (0V DC) ( 12 mA absorption, max) (1
sq.mm)
PIN3 IN SEALING SIGNAL FROM PLC, 24V DC (0V DC) ( 12 mA absorption, max) (1 sq.mm)
PIN4 IN RESET SIGNAL FROM PLC, 24V DC (0V DC) ( 12 mA absorption, max) (1 sq.mm)
PIN5 IN CALIBRATING SIGNAL FROM PLC, 24V DC (0V DC) ( 12 mA absorption, max) (1
sq.mm)
PIN6 OUT SEALING FAULT (CONTACT N.C.) cosΦ = 1 250V 8A (1 sq.mm)
PIN7 OUT SEALING FAULT (CONTACT N.C.) cosΦ = 0.4 250V 5A (1 sq.mm)

CN4 DISPLAY PANEL CONNECTOR (15 PIN FEMALE)
PIN1 +5Vcc Screened (0,25mmq)
PIN2 0 V Screened (0,25mmq)
PIN3 SPI-SDO Screened (0,25mmq)
PIN4 SPI-SCK Screened (0,25mmq)
PIN5 SPI-SDI Screened (0,25mmq)
PIN6
PIN7
PIN8
PIN9 SPI-SS Screened (0,25mmq)
PIN10 RESERVED Screened (0,25mmq)
PIN14
PIN15
NOTE 1: The cable termoregulator-panel must be screened, pin to pin connected - Max Mt 15.
CN5 RS 485 SERIAL INTERFACE CONNECTOR (9 PIN FEMALE)

PIN3 Channel B+ Screened (0,25mmq)
PIN8 Channel A- Screened (0,25mmq)
NOTE 1: Twist the cables
CN6 REFERENCE TERMINAL BLOCK

PIN1 SEALING BAND REFERENCE REF- (0,5mmq)
PIN2 SEALING BAND REFERENCE REF+ (0,5mmq)
PIN3 SCREEN REFERENCE CABLE REF 0 (Don't connect on machine side) (1mmq)
PIN4 REFERENCE TA- (0,5mmq)
PIN5 REFERENCE TA+ (0,5mmq)
PIN6 SCREEN TA CABLE TA0 (Don't connect on machine side) (1mmq)
NOTE 1: Twist cables or better use cable TWINAX IBM (Ns. cod. 3esd0066)
CN7 POTENTIOMETER CONNECTOR (9 PIN MALE)

PIN1 PRE-HEAT POTENTIOMETER +4,58V Screened (0,25mmq)
PIN2 PRE-HEAT POTENTIOMETER RIF+ Screened (0,25mmq)
PIN3 PRE-HEAT POTENTIOMETER 0V Screened (0,25mmq)
PIN4 Connect PIN3 to PIN4 Screened (0,25mmq)
PIN5
PIN6 SEAL POTENTIOMETER +4,58V Screened (0,25mmq)
PIN7 SEAL POTENTIOMETER RIF+ Screened (0,25mmq)
PIN8 SEAL POTENTIOMETER 0V Screened (0,25mmq)
PIN9 Connect PIN 8 to PIN9 Screened (0,25mmq)
NOTE 1: If conneted to PLC analog output use PIN2,PIN3,PIN7,PIN8 and leave free PIN4-PIN9
NOTE 2: Twist cables or better use cable TWINAX IBM (Ns. cod. 3esd0066)

2.2 ELECTRIC DRAW – DIGITAL CONNECTIONS

2.2 ELECTRIC DRAW – POWER CONNECTIONS (CONTROL OF THE SECONDARY)
NOTE -
Power supply ( CN1/1 e CN1/2 ) must be with the same phase as
control supply ( CN2/3 e CN2/2 ).
Ground screw must be connected to the ground of machine, with the cable jellow green section
> = power cable section.
Twist power cable, twist TA cable
Twist and screen sealing reference cable

2.2 ELECTRIC DRAW – POWER CONNECTIONS (CONTROL OF THE PRIMARY)
NOTE -
Power supply ( CN1/1 e CN1/4 ) must be with the same phase as
control supply ( CN2/3 e CN2/2 ).
Ground screw must be connected to the ground of machine, with the cable jellow green section
> = power cable section.
Twist power cable, twist TA cable
Twist and screen sealing reference cable

3 INSTALLATION
3.1 – ANALYSIS OF APPLICATION
BEFORE BEGINNING THE FIRST INSTALLATION, READ CAREFULLY THE

WARNINGS AT CHAPTER 0 AND PARTICULARLY THE SAFETY PRECUTIONS AT
CHAPTER 0.1 AND COMPLIANCE WITH ELECTRO-MAGNETICS STANDARDS AT
CHAPTER 0.2.
IT IS ENOUGH FOLLOW STEP TO STEP THE FOLLOWING INSTRUCTIONS TO START

UP THERMOREGULATOR WELL; FOR ANY QUESTIONS DON’T EXITATE TO
CONTACT OUR TECHNICAL OFFICE.
• WHICH BAND CAN USE TO HAVE THE MAXIMUM?

If You like You can contact our technical office to choise band
Material:
• Original bands by 3E in special alloy Good
• NiCr80/20 No good
• Altro: Contact our technical office
Profile:
• Chamfered (tapered edge) …………………….

• Flat …………………….
• Concave (grooved) …………………….
• Double …………………….
• Beaded …………………….
• T-Shape …………………….
• Cutting wire …………………….
• Endless steel bands …………………….
• Other …………………….
Geometrical Dimensions:
• Width: LARG= ……………………. [mm]

• Thickness: SP= ……………………. [mm]
• Length : L-TOT= ……………………. [mm]
• Copper/Silver Ends: L-RAM= ……………………. [2 x mm]
• Copper/Silver in the center: L-RAMC= ……………………. [mm]
• Teflon in the center: L-TEFL= ……………………. [mm]
• Other: …………………….

• CALCULATION OF THE USABLE BAND LENGTH
It’s the length of the part not coppered; it’s calculated by the following formula:
L-UTIL = LTOT – (LRAM x 2) – LRAMC)
Usable length: L-UTIL = ……………………. [mm]
• CALCULATION OF THE BAND SECTION

The band section is calculated by the following formula:
SEZ = LARG x SP in mmq
Section: SEZ = ……………………. [mmq]
3.2 - CALCULATION OF SEALING BAND RESISTANCE
If You USE AN ORIGINAL band 3E included in the underlying tables, You can calculate band resistance using the
tables and applying the following formula:
1– single band = R-BAND = R0 x L-UTIL [ mt. ]

2– 2 bands in series = R-BAND = R0 x L-UTIL x 2 [ mt. ]
3– 2 bands in parallel = R-BAND = R0 x L-UTIL / 2 [ mt. ]
R0 = Specific resistance of the band [ Ω / mt ]

L – UTIL = Usable length of the band [ mt. ]
If You DON’T USE AN ORIGINAL band 3E included in the underlying tables, You must measure the band resistance
directly on te contact with a precision instrument.
Resistance: R-BAND= ……………………. [Ω]

3.3 - THERMOREGULATOR CHOISE
• WHAT TYPE OF THERMOREGULATOR IS TO CHOOSE ?

-SECONDARY 60 AMPERE? (ICC= 60 x 2.5 = 150 AMPERE)
-SECONDARY 90 AMPERE? (ICC= 90 x 2.5 = 225 AMPERE)
-PRIMARY 120A? (ICC=120 x 2.5 = 300 AMPERE)
-STANDARD OR LOW VOLTAGE?
It depends from the HEATING CURRENT as following:

calculate the section of the band, if serial or parallel; in the case of parallel the section is twice.
If we think a current of 30 Ampere/mmq (from experience, for more informations contact our technical office) we have the
following:
I HEATING =BAND SECTION S[square mm] x 30[Amp/squaremm]
The thermoregulator must have a nominal current more then I HEATING.
SAMPLES:
CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD

4 x 0,25 1 30 Amp 60
5 x 0,2 1 30 Amp 60
6 x 0,2 1,2 36 Amp 60
8 x 0,15 1,2 36 Amp 60

4 x 0,25 x 2 2 60 Amp 60
5 x 0,2 x 2 2 60 Amp 60
6 x 0,2 x 2 2,4 72 Amp 60-90
8 x 0,15 x 2 2,4 72 Amp 60-90

8 x 0,2 x 2 3,2 96 Amp 90-120

3.4 - POWER TRANSFORMER CHOISE
• WHICH TRANSFORMER IS TO CHOOSE?

The choise depends on I heating current and resistance.
At the first start up it’s better to use transformers multivoltage original by 3E, specific for the thermoregulators 60 Ampere,
90 Ampere, with control of the secondary, with control of the primary; for the following applications it’s possible to
manufacture specific transformers lower cost by 3E or to supply electric features (see append F).
• WHICH VALUE OF SECONDARY VOLTAGE?

It’s calculate from I heatin current and band’s resistance:
(VOLT SECONDARY = R-BAND x I HEATING)
- Sample:
It’s to connect a band with 0,4 Ohm of resistance, section 2 sqmm, heating current will be 60 Ampere (30Ampere x 2sqmm)
and the voltage of secondary will be 24 Volts (0.4 ohm x 60 Ampere)
Transforer: POWER = ……………………. [ VA ]

PRIMARY = ……………………. [V]
SECONDARY = ……………………. [V]

3.5 - PROTECTION DEVICE CHOISE
• WHICH PROTECTIVE DEVICES ARE TO CHOOSE? (MODULATION ON THE SECONDARY)
On the 220 Vac supply voltage of the logic, 2 fuses inside the thermoregulator protect the internal transformer.
It’s necessary protect only the 220 Vac supply cables from short circuit in compliance with the normes IEC204.1
On the power supply, the transformer must be protect on the primary and secondary; protective devices depends on
the HEATING CURRENT on the secondary and the same rated to the primary.
Use the D curve protections (or delay fuses)
The protections suggested must be verified by the designer in compliance with the application.
• WHICH PROTECTIVE DEVICES ARE TO CHOOSE? (MODULATION ON THE PRIMARY)
On the 220 Vac supply voltage of the logic, 2 fuses inside the thermoregulator protect the internal transformer.
It’s necessary protect only the 220 Vac supply cables from short circuit in compliance with the normes IEC204.1
On the power supply, the transformer must be protect on the primary; on the secondary it’s possible to connect
directly the transformer to the band, without protections, because of an active protection inside the termoregulator
by the T.A. circuit; protective devices depends on the HEATING CURRENT on the secondary rated to the primary.
Use the D curve protections (or delay fuses)
The protections suggested must be verified by the designer in compliance with the application.

3.6 – ADVICES TO DEVELOP ELECTRIC CONNECTIONS
• WHICH ACTIONS ARE TO DO, TO HAVN’T PROBLEMS DURING STARTING UP?
Use original power transformers by 3E

For the first start up, we recommend to use the original multi-voltage power transformers by 3E, specific for the
thermoregolators 3E.
For the following start up we can supply original single voltage power transformers by 3E, lower cost.
If You prefer to use a different transformer from above refer to technical characteristic on this book, see ANNEX F –
MULTIVLTAGE TRANSFORMER TECHNICAL FEATURES.
Use original bands by 3E in special alloy

For the first start up this is indispensable.
For the following start up, we advise to continue to use the original bands to don’t loose stability.
In the market You can find other good bands; don’t use bands of any materials; for informations contact our commercial
office.
Execute wiring as advised in the WIRING NOTE and in the FOLLOWING PICTURES (SEE FOLLOWING
PAGES)
Pay much attention to the connections on the machine of the reference wire and of the power cables to have no problems at
starting up and in the future; contact our technical office for more informations.
Connect in phase the supply of logic (230 Volts) with the primary of power transformer (230Vac o 380 Vac).
The 230V of logic must be:
1 – The same of the primary of the power transformer (if the primary of the power transformer is 230V)
2 – In phase or out of phase 180 degree, originated by a little transformer es. 30VA - 0-400 / 0-230 (if the primary of the
power transformer is 400V)
Read diagnostic warning and act accordingly

If it happens to have some problems during start up or later, read and pay attention at the alarm number that appears on the
display panel; read the cause and the remedy in this book, see append D, and act accordingly; if the problems persist don’t
exitate to contact our technical office: the diagnostic permit to us to help You to solve problems also at distance.
It’s better to position the panel cable far from cables supplying high currents or other electrical noise sources.
In any case the panel cable is screened and protected from electrical noise.
Mount the thermoregulator leaving a rigth space around for cooling:

8 cm about for model 60 Ampere
10 cm about for model 90 Ampere

CONNECTIONS TO SINGLE BAND

CONNECTIONS IN PARALLEL (SUGGESTED)

CONNECTION IN PARALLEL (ALTERNATIVE)
ATTENTION!!!
(CONNECT ONLY 2 REFERENCE CABLES - couple 3-6 or 4-5)
(NEVER USE ALL 4 REFERENCE CABLES TOGETHER)
OBSOLETE

• CHAMFERED SPECIAL ALLOY ELEMENTS RESISTANCES CHART
Band width Band thickness Specific resistance R0

(mm) (mm) Ω / mt
1.5 0.3 1.67
2 0.25 1.59
3 0.1 2.95
3 0.15 1.95
3 0.2 1.50
3 0.25 1.27
4 0.15 1.40
4 0.25 0.96
5 0.2 0.8
5 0.25 0.69
6 0.1 1.6
6 0.2 0.72
8 0.1 1.2
8 0.2 0.51
• T-SHAPE SPECIAL ALLOY ELEMENTS RESISTANCES CHART

(mm) (mm) Ω / mt
2.8 0.3 0.9
4 0.3 0.6
• BEADED SPECIAL ALLOY ELEMENTS RESISTANCES CHART

(mm) (mm) Ω / mt
4 0.15 1.4
4 0.25 0.9
6 0.15 0.99
6 0.25 0.6

• CONCAVE SPECIAL ALLOY ELEMENTS RESISTANCES CHART

(mm) (mm) Ω / mt
2.8 0.3 0.9

4 START UP
4.1 - START UP PROCEDURES – INSPECTING THE SYSTEM AND THE PARTS USED
Stage 1 – In order to properly set up the system, read the instructions given in paragraph 4.8 THEORETIC
CALCULATIONS AND DIAGNOSTIC PROCEDURES and 4.9 SETUP PROCEDURES WITH THE AID OF
THE MULTI-LINGUAL CONTROL PANEL
Stage 2 – Use a Low Voltage Unit for power transformer outputs up to 10 Volt
Use a Standard Unit power transformer outputs from 11 to 99 V.
Use a High Voltage Unit for power transformer outputs from 100 to 140 V.
Use Primary mode for pulsed currents more than 220Amps.
Stage 3 – Make the system contructed in an workmanshiplike manner.
Stage 3.1 – Use sealing bands supplied by our Company or equivalent (don’t use NI-CR sealing bands).
Stage 3.2 – The power cable inside the T.A. must not turn around T.A (only 1 single line inside).
Stage 4 – For any further information, call 3E – ENGINEERING DEPARTMENT.
TECHNICAL NOTES
From software V5.1 it’s possible modify the temperature coefficient of the sealing bands in part per milion PPM; modifying
the PPM also other parameters will change in automatic as shown in the following table; for compatibility with the previous
models the thermoregulator outputs from our factory with the default temperature coefficient PPM=1465 that maintain the
heating characteristic and the voltage of the analog input unchanged.
TABLE OF PARAMETERS DEPENDING ON TEMPERATURE COEFFICIENT
Master Reset
PPM= 1465 1300 1100 1000 913 750
BIT/°C= 1465:488=3 1300:488=2.6 1100:488=2.2 1000:488=2.0 913:488=1.8 750:488=1.5
T.MAX[°C]= 300 1000:2.6=384 1000:2.2=454 1000:2.0=500 1000:1.8=555 1000:1.5=666
IN. ANALOG.[ mv/°C] 4V/300=13.33 4V/384=10.42 4V/454=8.81 4V/500=8.00 4V/555=7.21 4V/666=6.00
POT.(°C/GIRO) 300/10=30 384/10=38.4 454/10=45.4 500/10=50 555/10=55.5 666/10=66.6
NOTE: 488, 1000, 4V, 10 are constants

4.2 - PUTTING THE SYSTEM INTO SERVICE – BASIC SETUP (+RS485 OPTION)
PRE-HEAT
POTENTIOMETER
HEAT-SEALING
POTENTIOMETER
CLEAR FAULTS/RESET
BUTTON
CALIBRATION BUTTON
Step 1 – Calibrate the system after performing the steps indicated in paragraph 4.1.
Step 2 – The machine should be at ambient temperature
Step 3 – The pre-heat and heat-sealing controls should be inactivated
Step 4 – Power up the temperature controller
Step 5 – In the event of faults (the Red ALARM Led lights up), follow the instructions given on the temperature regulator
and put the faults right as required (the id. number of the fault can be found by multiplying the pulses emitted by the green
Balance Led by 10 (e.g. 9 pulses= 90) + the pulses of the red Balance Led by the units (e.g. 10 pulses =0)
Step 6 – Calibrate the system. Keep the external CALIBRATION button pressed for 3 seconds and wait (the four LEDS on
the system go on flashing as long as the the instrument is being calibrated).
Step 7 – The system is ready to start cycling as soon as the calibration procedure has been completed. Set the Heat-Sealing
and Pre-Heat temperature by using the respective potentiometers (for resolution see technical note paragraph 4.1).
WARNING – If calibration problems arise, perform a MASTER RESET procedure starting from stage 5 ( to perform the
MASTER RESET procedure, keep the external RESET + CALIBRATION buttons pressed for 6 seconds; the 4 Leds on the
equipment stay on for 3 seconds).

4.3 - STURT UP THE SYSTEM INTO SERVICE – BASIC SETUP + MULTI-LINGUAL CONTROL PANEL
(+RS485 OPTION)
Step 1 – Carry out the calibration procedure after performing the steps indicated in paragraph 4.1.
Step 2 – Make sure the machine is at ambient temperature
Step 3 – The Pre-Heat and Heat-Sealing controls should be inactivated.
Step 4 – Power up the temperature controller
Step 5 – In the event of faults ( the Red ALARM LED on the temperature controller comes on), follow the instructions
given on the control panel and put the faults right as required (the number of the fault occured is displayed on the control
panel along with the relevant description in one of the 6 languages provided).
Step 6 – Calibration: keep the CAL button on the multi-lingual control panel pressed for 3 seconds as indicated in the
illustration below, Figure 3 (the four LEDS on the equipment go on flashing as long as calibration is being performed).
NOTE: For further calibration procedures, press buttons CAL+MODE+CAL on the multi-lingual panel in the order given .
Also refer to the illustration below, Figures 1+2+3:
Figure 1 Figure 2 Figure 3
NOTE: Calibration can be carried out from the "outside" as described in paragraph 4.2 with the basic setup.
Step 7 – The system is ready to cycle once the calibration procedure has been carried out. Set the Pre-Heat and Heat-
Sealing temperatures (press the MODE+MODE button in the sequence given to access the TEMPERATURE submenu -
refer to paragraph 4.7).
Step 8 – To go back to the initial display, press the RES button and follow the instructions given.

NOTE – If calibration problems arise, perform a MASTER RESET procedure starting from stage 5.
To perform a MASTER RESET procedure, use either of the two modes below:
mode 1 – Keep the ARROW DOWN + ARROW UP buttons pressed for 6 seconds.
mode 2 - Keep the external RESET+CALIBRATION buttons pressed for 6 seconds.
The four LEDS on the equipment stay on for 3 seconds
4.4 - PUTTING THE SYSTEM INTO SERVICE – BASIC SETUP + MULTI-LINGUAL PANEL +
POTENTIOMETERS (+RS485 OPTION)
PRE-HEAT POTENT.
HEAT-SEAL POTENT.
CLEAR FAULTS/ RESET

BUTTON
CALIBRATION BUTTON
NOTE 1: Perforn the same operations as those described in paragraph 4.3 above.
NOTE 2: To enable the potentiometers, change the MACHINE DATA items = 1, Potentiometers + display.
NOTE 3: Set the maximum pre-heat and heat-seal temperatures by using the control panel. To step them down, adjust the
analog inputs (for resolution see technical note paragraph 4.1).

4.7 - OPERATING THE MULTI-LINGUAL CONTROL PANEL
NOTe: The user can go back to the initial display from any video pages by pressing the RES button several times.
INITIAL DISPLAY LEVEL 1
NOTe: To scroll the sub-menus, press buttons MODE+ARROW DOWN

or ARROW UP in the order given.
TEMPERATURE SUBMENU LEVEL 2

DIAGNOSTIC SUBMENU LEVEL 2
EMERGENCY TEST SUBMENU LEVEL 2
BURN-IN SUBMENU LEVEL 2
DATA SETTING SUBMENU LEVEL 2
MACHINE DATA SUBMENU LEVEL 2
INFORMATION SUBMENU LEVEL 2
NOTE: Press buttons MODE+ARROW DOWN or ARROW UP to

access any submenu or parameter.
NOTE: To alter any parameter displayed, proceed as follow:

Press the MODE button to switch over to modification mode: ? 080
Press the ARROW UP button to alter any data item: ? 081
Press the MODE button to quit the modification mode: = 081

NOTE: Before saving any changes made, the system prompts the user to confirm the entry:
????ENTER????
YES=MODE NO=RES
Select YES to confirm, NO to restore the earlier data

4.8 - THEORETICAL CALCULATIONS AND DIAGNOSTIC PROCEDURES WITH THE AID OF THE DATA
INPUT PANEL
1) Access the DIAGNOSTIC – THEORETICAL CALCULATION submenu.
2) Enter the data that concern the shape of the strip: length, width, cross-section, number of strips in series, number of
strips in parallel.
3) Enter the data and quit.
DIAGNOSTIC
1) Select the DIAGNOSTIC – ANALISYS submenu.
2) Scroll the diagnostic video-pages by using the ARROW UP – DOWN buttons. These pages contain the electrical
specifications that concern the sealing strip: maximum effective currents, resistance, full-wave effective currents,
full-wave effective power.
3) Each video page indicates 3 values that relate to the same variable under different conditions i.e.: THEORETICAL
VALUES, CALIBRATION SETTINGS, REAL TIME VALUE, in particular:
PAGE 1: IMAX=
I0= I=
Where IMAX stands for the maximum pulsed effective currents of the temperature controller, I0 represents the full-
wave effective current for calibration and I is the actual full-wave effective current
PAGE 2: R THEORETICAL =
R0= R=
Where R THEORETICAL stands for the theoretical resistance of the temperature controller, R0 is the calibration
resistance and R represents the actual resistance.
PAGE 3: I THEORETICAL =
I0= I=
PAGE 4: V THEORETICAL =
V0= V=
PAGE 5: P THEORETICAL =
P0= P=
4) Particularlty useful information on the system conditions can be obtained

by comparing the three variables so that any malfunctioning and diagnostic
problems can be dealt with remotely.

4.9 - SETUP PROCEDURES WITH THE AID OF THE CONTROL PANEL
1) Enter the theoretical values (see paragraph 4.8 above)

2) Access the DIAGNOSTIC – ANALYSIS submenu (see paragraph 4.8 above)
3) Read the effective pulsed voltage of the strip, THEORETICAL V.
4) Set the transformer secondary voltage allowing for a multiplication coefficient of 1.5 – 2 for pulsed operation and a
coefficient of 1.5 for continuous operation:
transformer V = strip V x multiplication coefficient (1.5 - 2), select the nearest one.
4.10 - SETUP PROCEDURES WITHOUT USING THE CONTROL PANEL – MANUAL MODE
Calculating total resistance:

R strip=specific resistance[Ohm/m] x strip length[m]
Calculating the strip cross-section S:
Strip cross-section S[mm2]=strip length[mm] x strip thickness[mm]
Calculating the theoretical pulsed heating currents I:
I heating=strip cross-section S[mm2] x 30[Amp/ mm2]
Calculating the effective pulsed voltage applied to the strip:
V strip=R strip x I heating
Calculating the transformer secondary voltage allowing for a multiplication coefficient of 1.5 – 2 to increase the
sealing speed under pulsed operating conditions and coefficient 1 for continuous operation:
V transformer= V strip x multiplication coefficient (1.5 - 2)
(select the nearest one)

5 MAINTENANCE
5.1 – CHANGING THE SEALING BANDS WITH MACHINE COLD ( i.e. gripper jaws at ambient temperature )
• HAVE YOU TO CHANGE THE SEALING BANDS WITH THE MACHINE AT AMBIENT TEMPERATURE,
BECAUSE OF A PROGRAMMED MAINTENANCE?
Pre-heat and seal comands are off; the machine is at ambient temperature; The sealing bands have little differences in
measure; for optimum accuracy it is possible to do an automatic cold balance to compensate the differences; it is possible
doing a burn-in cycle after, to become stable electric characteristics.
1 – Switch off power, release pre-heat and seal commands, let the gripper jaws getting cold down.
2 – Install the new sealing bands, switch on power.
3 – Make the CALIBRATING

Normally is not necessary change ambient temperature (gripper jaws temperature) in the SETTING DATA and doing a burn
in cycle at the end of calibrating.
4 - THE MACHINE IS READY TO WORK.

5.2 – CHANGING THE SEALING BANDS WITH MACHINE HOT
( i.e. gripper jaws cooling down , but hot too because of inertia )
• HAVE YOU TO CHANGE THE SEALING BANDS WITH THE MACHINE HOT, WITH THE
PRODUCTION IN PROGRESS, WITHOUT WAITING THAT GRIPPER JAWS TEMPERATURE FALLS
DOWN AT AMBIENT TEMPERATURE?
A sealing bands change, with the machine hot, with the production in progress, is less accurate then a change with the
machine cold, in a programmed maintenance, because the automatic cold balancing must not be done (an automatic cold
balance is done to compensate the differences in measure of the sealing bands).
If the application needs a very high precision, it is possible doing a quick change of the all gripper jaws with sealing bands,
and go on with the preceding procedure of CHANGING THE SEALING BANDS WITH MACHINE COLD(see par. 5.1).
Another less expensive way to work, but easier to make a mistake, is to set the parameter of ambient temperature at the
gripper jaws temperature and doing an automatic cold balancing (do not exitate to contact our technical office)
1 – Switch off power, release pre-heat and seal commands, let the gripper jaws cooling down.
2 - Install the new sealing bands, switch on power.

- If the machine is hot, must not do the automatic cold balancing.
3 – Only if necessary do the BURN-IN CYCLE.

- Verify if burn-in is necessary in the specific application, looking at the quality of the first seal.
4 - THE MACHINE IS READY TO WORK.

5.3 – TROUBLESHOOTING
• PROBLEM: Allarm Fxxx appears on the display - VERIFY alarm list in this book (ANNEX D)
• PROBLEM: In Balancing the band is hot - VERIFY that logic and power supply are in the same phase
• PROBLEM: On the display You can see oscillating temperature - VERIFY that contacts of bands are good,
Verify that connections are not linked together, verify machine data and, if they are not regular, do a master reset and a
following calibration with machine cold.
5.4 – THERMOREGULATOR MAINTENANCE

Depend on the working environment, in every way not more then every 180 days.
1 – Verify that all the thermoregulator terminals are screw tight
2 – Verify the right function of the emergency output floating contact (press the key mode as requested at power on
periodically; the output relay must open power circuit)
5.5 – GRIPPER JAWS MAINTENANCE

Depend on the working environment, in every way not more then every 20 days.
1 – Verify that the reference and power terminals are screw tight
2 – Verify that the connections of the bands are good without oxidation.
3 – Verify the teflon and the isolation of gripper jaws

6 SPECIFICATIONS
6.1 SPECIFICATIONS – MODELS WITH CONTROL OF THE SECONDARY
LOGIC CIRCUIT SUPPLY ( CN2 ) 230Vac +/- 10% ( 0.1 A absorption )

POWER CIRCUIT SUPPLY MODEL SECONDARY 10 - 100V
MAXIMUM SHORT CIRCUIT CURRENT MOD. 60 A 150 AMP
MAXIMUM SHORT CIRCUIT CURRENT MOD. 90 A 260 AMP + 10%
MAINS FREQUENCY 50 - 60 Hz (automatic changing )
DIGITAL CONTROLS 24 VDC (12 mA max. absorption )
OUTPUT SEALING FAULT CONTACT 250 V 8A cosΦ = 1 250V 5A cosΦ = 0.4
ACCURACY ≅ +/- 1 °C
PRE-HEATING TEMPERATURE can be set from display console, 0 - 250 °C
SEALING TEMPERATURE can be set from display console, 0 - 250 °C
SEALING TIME determined by PLC ( or precision timer)
COOLING TIME determined by PLC ( or precision timer)
AMBIENT TEMPERATURE 0° C +50° C
LEVEL OF BOARD PROTECTION IP00
LEVEL OF DISPLAY CONSOLE PROTECTION IP65
POWER ASSEMBLY WEIGHT 1,6 Kg
PANEL WEIGHT 0.2 Kg
PANEL-POWER ASSEMBLY EXTENSION WEIGHT 0.2 Kg
6.2 SPECIFICATIONS – MODELS WITH CONTROL OF THE PRIMARY
LOGIC CIRCUIT SUPPLY ( CN2 ) 230Vac +/- 10% ( 0.1 A absorption )

POWER CIRCUIT SUPPLY MODEL PRIMARY 230Vac +/- 10%
MAXIMUM SHORT CIRCUIT CURRENT MOD. PRIMARY 300 AMP
MAINS FREQUENCY 50 - 60 Hz (automatic changing )
DIGITAL CONTROLS 24 VDC (12 mA max. absorption )
OUTPUT SEALING FAULT CONTACT 250 V 8A cos Φ = 1 250V 5A cos Φ = 0.4
ACCURACY ≅ +/- 1 °C
PRE-HEATING TEMPERATURE can be set from display console, 0 - 250 °C
SEALING TEMPERATURE can be set from display console, 0 - 250 °C
SEALING TIME determined by PLC ( or precision timer)
COOLING TIME determined by PLC ( or precision timer)
AMBIENT TEMPERATURE 0° C +50° C
LEVEL OF BOARD PROTECTION IP00
LEVEL OF DISPLAY CONSOLE PROTECTION IP65
POWER ASSEMBLY WEIGHT 1,6 Kg
PANEL WEIGHT 0.2 Kg
PANEL-POWER ASSEMBLY EXTENSION WEIGHT 0.2 Kg

7 DETAILS FOR ORDER FORM
7- DETAILS FOR ORDER FORM
MODEL: - Description CODE
THERMOSALD ISC - Impulse Thermoregulator 100V 60A 3ES080DH

THERMOSALD ISC - Impulse Thermoregulator 100V 90A (obsolete) 3ES081DH
THERMOSALD ISC - Impulse Thermoregulator 100V 60A on PRIMARY 3ES082DH
THERMOSALD ISC - Impulse Thermoregulator 100V 90A 3ES083DH
PANEL - Multilanguage Panel data input 3ES080DL
PANEL RS485 - Multilanguage Panel data input connection RS485 3ES080DM
CAVO - Cable panel-Thermoregulator 3ES080A001
TA - Amperometric Transformer 3ES080A002
CORNICE ADATT. - Aluminum molding for mounting ISC panel on old 3ES080A003
machines with old UPSCR panel
OPTIONS:
RS485 - Option serial interface RS485 3ES080DZ=485
INAN - Option analog input 3ES080DZ=INAN
LOWVOLT - Opzione low volts 3ES080DZ=LOVL
- OPTIONAL EQUIPMENT:
TRANSFORMER 2100VA/70V/30A 3ESD0063
Impulsive transformer for Thermoregulator 60 Ampere
0 / 230 / 400 / SCH / GND = 0 / 30 / 40 / 50 / 60 / 70
0 / 230 / 400 / SCH / GND = 0 / 30 / 40 / 50
0 / 230 / 400 / SCH / GND = 0 / 20 / 30
TRANSFORMER 3000VA/15V/200A (PER PRIMARIO) 3ES082A001
Impulsive transformer for Thermoregulator 120 Ampere on PRIMARY
0 / 230 / 400 / 500 / 900 / SCH / GND = 0 / 15
SEALING BANDS WIRES ENDLESS BELT
Bands, wires and endless belts with many profiles, selled in meters, on specific draw,
Copper/Silver ended, teflon coated.
THERMOSALD_485 – Supervisor simulator for RS485 3ESD0075
(CD + Box RS232-RS485)
- MANUALS:
ITALIAN COMMERCIAL CATALOGUE 3ES080x_Vx_CO_IT
ITALIAN QUICK START MANUAL 3ES080x_Vx_QS_IT
ITALIAN MAINTENANCE & OPERATOR MANUAL 3ES080x_Vx_MU_IT
ENGLISH COMMERCIAL CATALOGUE 3ES080x_Vx_CO_EN
ENGLISH QUICK START MANUAL 3ES080x_Vx_QS_EN
ENGLISH MAINTENANCE & OPERATOR MANUAL 3ES080x_Vx_MU_EN
FRENCH MANUAL QUICK START MANUAL 3ES080x_Vx_QS_FR
GERMAN MANUAL QUICK START MANUAL 3ES080x_Vx_QS_DE
SPANISH MANUAL QUICK START MANUAL 3ES080x_Vx_QS_SP

ANNEX A – TYPICAL SEALING CYCLE
NOTE - The sealing cycle showed bottom is only for example and not a standard cycle to follow
everytime. From experience we have learnt that it’s necessary modify the cycle depending on materials,
dimensions, speeds and else. For other informations don’t exitate to contact our technical office.
SEALING CYCLE
PRE-HEATING
SIGNAL
(IN THERMOSALD)
SEALING SIGNAL
(IN THERMOSALD)
closed
FILM GRIPPER JAWS

open
closed
BAND SEALERS
open
COOLING
FILM FEED

ANNEX B – MACHINE DATA LIST
NOTE – The machine data must be changed only by skilled workers with experience, after getting in contact with
our technical office; the necessity to change some machine data, may be in specific applications.
TO ENTER: from secondary menu MACCHINE DATA press key MODE.

TO OUTPUT: press key RES and follow guide.
• RATED CURRENT = 60 / 90 / 120 (AMPERE)

Not changeable, it shows the nominal current of the model used (conseguently the short circuit current will be
I_short_circuit=Inominal x 2.5)
• HEATING INCREASE DEGREE / 10 MS = 4 (U.M.)
It is the speed of temperature increase following a pre-heat or a sail comand [Units degree / 10 ms].
Increase this parameter means decrease time necessary to hot the sealing band to pre-heat temperature, i.e. increase
speedy, increase overshoot, increase bands wear and tear.
• PROPORTIONAL GAIN KV = 100 (U.M.)
Loop integral gain. Increase this parameter means to increase the precision of the target temperature, increase the
speedy, increase the stability of the system.
Increase too much means to introduce a temperature overshoot following a pre-heat or sealing command.
• INTEGRAL GAIN KI = 100 (U.M.)
Loop integral gain. Increase this parameter means to increase the precision of the target temperature, increase the
speedy, increase the stability of the system.
Increase too much means to introduce a temperature overshoot following a pre-heat or sealing command.
• KI OPERATING LIMIT = 60 (%)
Limits the maximum value of the integral gain KI; increasing this value, overshoot with the machine cold increases.
• DERIVATIVE GAIN KD = 40 (U.M.)
Loop derivative gain. Increase this parameter means increase speed of the loop and then increase speed of the system.
Increase too much means to do the system and temperature less stable.
• TEMPERATURE COEFFICIENT (PART PER MILION) = 1465 (PPM)
This parameter modify the temperature characteristic of the thermoregulator, in part per milion.
Increase this parameter means increase the temperature of the band (1465 is the default value to have the total
compatibility with the previous thermoregulators. From software V5.1
RESOLUTION (3 UNITS / DEGREE)
This value is the internal units per degree; change with the TEMPERATURE COEFFICIENT.
• PARTIAL SHORT CIRCUIT FACTOR = 1.1 (U.M.)
This parameter is used to set an istantaneous current threshold, above which a partial short-circuit occurs and the
thermoregulator sends fault signal F097.
• FAULT DISABLE = 0 (U.M.)
Disable any alarm; use much caution; sometime it can help to continue the production; alarm disable must be considered
temporary and it’s necessary understand immediately the cause of the trouble.
• CONFIGURATION (MODE) = 0
The thermoregulator is designed to develope 2 type of functions:
0 = standard function IMPULSE SEALING.
1 = function HOT BAR.

• CONFIGURATION PANEL = 2
The thermoregulator is designed for 5 type of functions:
0 = function only with potentiometers (at first start up)
1 = function with potentiometers and display: the temperature set on display in pre-heat and seal is the maximum value,
with potentiometers can decrease (also with analog input).
2 = function only with display.
3 = predisposed for CAN BUS
4 = predisposed for PROFIBUS
• CONFIGURATION (SERIAL INTERFACE) = SERIAL 485 OFF
Thermoregulator can exchange data with supervisor by RS485 interface.
• SERIAL ADDRESS RS485 = 0
Unit address for serial interface RS485; value admitted 0-15

ANNEX C – SETTING DATA LIST
NOTE – The setting data must be changed only by skilled workers with experience, after getting in contact with our
technical office; the necessity to change some machine data, may be in specific applications.
TO ENTER: from secondary menu SETTING DATA press key MODE.

TO OUTPUT: press key RES and follow guide.
• LANGUAGE SELECTION = ITALIAN

It’ possible select up to 6 language: ITALIAN, ENGLISH, FRENCH, GERMAN, SPANISH, FREE
• DEGREES SELECTION = CELSIUS
Select the temperature display in Celsius or Farheneit degrees.
• CALIBRATING TEMPERATURE = 30 (DEGREE)
Set the calibrating temperature; it inform the thermoregulator of the sealing band temperature at the time of calibrating;
if machine is cold the calibrating temperature is equal to the ambient temperature.
• MAXIMUM SEALING TEMPERATURE = 250 (DEGREE)
Limit of the temperature set in pre-heat and seal, maximum value settable is 300°C; from software V5.1 the maximum
value depends on the TEMPERATURE COEFFICIENT and is readable in this page on the right of display.
• MAXIMUM SEALING TIME = 0.0 (SECONDS)
Set the maximum sealing time; if sealing time is longer than this value, thermoregulator sends fault signal F085.
000 means that control is not active and it is possible to do continuos sealing.
• BURN IN TEMPERATURE = 160 (DEGREES)
Hot temperature in a burn-in cycle.
Note: the burn-in cycle is used to stabilize bands in temperature; it executes 3 cycles of heating and cooling .
• BURN IN TIME = 30 (SECONDS)
Heating time in seconds of the Burn_in cycle.
Nota: the Burn-in cycle is used to stabilize bands in temperature; it executes 3 cycles of heating and cooling .
• BURN IN CYCLE NUMBER = 3 (U.M.)
Numbers of heating and cooling phases in a burn-in cycle; a standard burn-in cycle includes 3 phases of heating at burn-
in temperature and 3 phases of cooling at 100 degrees.
• TEMPERATURE GRADIENT FOR CALIBRATING START (DEGREES/10SECONDS)
Indica la massima velocità di raffreddamento della temperatura in gradi/10secondi, sopra la quale il bilanciamento non è
abilitato e compare warning 38. Se aumentiamo questo parametro si può perdere precisione.
• Set the maximum speed of cooling in degrees/10seconds; upper this value the calibrating is disabled and a warning 38 is
displayed. Increasing this parameter can loose precision of calibrating.
• ENABLE COMPENSATION WITH SYSTEM COLD (SCC) = 0 (U.M.)
Not developed; enable the special function of a different initial seal temperature. For more informations do not
Exitate to contact our technical office.
• SEAL TEMPERATURE WITH SYSTEM COLD (WITH SCC=1) = 220 (GRADI)
Not developed; it’s the seal temperature of the first seals, when temperature of the band is less then structure
temperature. For more informations do not exitate to contact our technical office.
• STRUCTURE TEMPERATURE WITH SYSTEM COLD (WITH SCC=1) = 80 (GRADI)
Not developed; if sealing band temperature is less then structure temperature, the seal temperature will be equal to
SEAL TEMPERATURE WITH SYSTEM COLD. For more informations do not exitate to
contact our technical office.
• TIME WARN66 = 3 (SECONDS)
In the case of frequency instability, caused by power factor correction, the thermoregulator display warning 66, without
to stop the production; this parameter indicates the seconds that the message is displayed.
• SET TEMPER.PAG1 = 0
Set=1 to select SETTABLE SEAL TEMPERATURE DIRECTLY IN THE MAIN PAGE.

ANNEX D – FAULT AND WARNINGS LIST (CAUSES – REMEDIES)
NOTE - To reset every alarm give external reset command or press reset button RES on the panel
NOTE – when an alarm happens, on the thermoregulator the led red of alarm light; it’s possible to know the number
of alarm reading the multilanguage panel or reading the number of lightening of led red and green:
ALARM NUMBER = NR. IMPULSES OF LED GREEN x 10 + NR.IMPULSES LED RED
WARNING - ALARM CAUSES

Remedies
ALARM A TERMOREGULATOR OFF AND DISPLAY OFF

Verify power, Logic supply fault, call the supplying builder.
ALARM B TERMOREGULATOR WITH LED OFF AND DISPLAY ON
Circuit of synchronisme fault, call the supplying builder.
ALARM C TERMOREGULATOR WITH LED ON AND DISPLAY ON AND INDICATION
"3E SRL + THERMOSALD"
Verify cable connection display
F06 DISPLAY EEPROM FLASH WRITE
Switch off and switch on the equipment and call the supplier
F07 A/D CONVERTER
Switch off and switch on the equipment and call the supplier
F08 INTERNAL TRASMISSION I2C-X
Switch off and switch on the equipment
F09 INTERNAL TRASMISSION I2C-EEPR
Switch off and switch on the equipment and verify parameters
F19 RS485 MASTER - CHECKSUM ERROR
Verify checksum selection on the Master or Slave
F20 RS485 SLAVE - CHECKSUM ERROR
Verify checksum selection on the Master or Slave
F21 RS485 SLAVE - OE ERROR-OVERRUN
Following data arrived before reading the previous
F22 RS485 SLAVE - FE ERROR-FRAME ERROR
Data stop bit not arrived
F23 RS485 MASTER – NO ANSWER FROM SLAVE
After a Master calling no answer received from the slave
F24 RS485 SLAVE – TOO DATA REQUESTED FROM MASTER OR WRONG ADDRESS
Master ha s requested to the slave too many data or a wrong address
F25 RS485 SLAVE – BUFFER FULL
Slave Buffer is full because of too many data trasmitted or too frequently trasmitted
F26 RS485 MASTER - OE ERROR-OVERRUN
Following data arrived before reading the previous
F27 RS485 MASTER - FE ERROR-FRAME ERROR
Data stop bit not arrived
F28 RS485 MASTER - TOO DATA REQUESTED FROM SLAVE OR WRONG ADDRESS
Slave ha s requested to the master too many data or a wrong address
F29 RS485 MASTER - BUFFER FULL
Master Buffer is full because of too many data trasmitted from the slave
F33 NO VOLTAGE ON POWER TRASFORMER
Verify power on CN1/L1,L2, verify power trasformer circuit
F34 DON'T USE
F35 CALIBRATION REQUEST

Used in distance control RS485
F36 CALIBRATING IN PROGRESS
Used in distance control RS485 to know when calibrating end.
F38 THE MACHINE IS WAITING A COOLING DOWN DURING A CALIBRATION PROCEDURE
Wait please
F46 NO CURRENT SIGNAL
Verify sealing band connection,TA connection
F47 TA SIGNAL WRONG TURNED
TurnTA connection
F48 PRE-HEATING POTENZIOMETER NO CONNECTED OR CABLES BROKEN
Verify pre-heating potenziometer connections and cables
F49 SEALING POTENZIOMETER NO CONNECTED OR CABLES BROKEN
Verify sealing potenziometer connections and cables
F51 WIPER-I
Switch off and switch on the thermoregulator; if problem persist call the supplying
F52 WIPER-V
F53 WIPER-VGROSS
F54 WIPER-VFINE
F60 RESET WITH CALIBRATING IN PROCESS
Repeat the calibrating
F61 BALANCE UNSUCCESSFULL
F62 BALANCE V UNSUCCESSFULL
F63 BALANCE VGROSS UNSUCCESSFULL
F64 BALANCE VFINE UNSUCCESSFULL
F65 BALANCE UNSUCCESSFULL
F66 MAIN PHASE SYNCHRONISM
Reset the thermoregulator if problem persist call the supplying
F69 CURRENT TO GROUND
Verify sealing bands in the machine touch ground.
F71 FAULT HARDWARE –15V INTERNAL
Reset the thermoregulator; if problem persist call the supplying
F72 FAULT HARDWARE +15V INTERNAL
F73 FAULT HARDWARE +5V INTERNAL REFERENCE
F76 IREAD TOO HIGH
Verify if short circuit on the seals
F78 THERMOREGULATOR NOT CALIBRATED
Do a calibrating
F79 FAULT OF EMERGENCY CIRCUIT
Verify contactor power, verify emergency chain

F081 FAULT HARDWARE - CHECK-SUM
Data in the eeprom wrong, pay much attention please
Press button RES, verify TEMPERATURE, SETTING, MACHINE, DATA;
call the builder
F082 LOGIC SUPPLY (CN2) AND POWER SUPPLY (CN1) HAVE DIFFERENT PHASES
Verify that the supplies have the same fase
F083 REFERENCE CABLE WRONG TURNED

Turn reference cable: (CN1/3 WITH CN6/1 - CN1/4 WITH CN6/2)
F085 SEALING TIME HIGHER THEN MACHINE DATA "SEALING TIME"

Increase machine data sealing time (If 0 the controll is off).
F089 BAND BROKEN IF THE BANDS ARE PARALLEL CONNECTED

Verify the bands.
F090 SHORT CIRCUIT BETWEEN THE BANDS OR BETWEEN A BAND AND GROUND IN THE
CASE OF HIGH CURRENT
Verify bands, verify power connection between thermoregulator and bands
F092 POWER PART FAILURE
F093 BAND BROKEN DURING A SEAL
Verify power on the transformer, Verify voltage on CN/1 CN/2 connector, verify breaking of power cables,
verify breaking of bands.
F094 REFERENCE SIGNAL CABLE FROM BANDS IS INTERRUPTED
Verify the connection of reference signal cable from band ( CN6/1 - CN6/2 )
F095 MAIN SUPPLY SYNCRONISM DOES NOT MUCH MACHINE REQUIREMENTS
Internal hardware problem, call the supplying builder
F096 FAULT V-I TOO HIGH
Saturation of the voltage circuit, verify connection, probable break of one seal, if seals in parallel.
F097 PARTIAL SHORT CIRCUIT BETWEEN THE BANDS
Verify bands into machine probably not perfectly isolated.
If the problem persist repeat burn-in procedure or do calibrating.
To reduce the problems increase machine data partial short circuit
F099 FAULT GENERIC
call the builder

ANNEX E – DIMENSIONS
PANEL BORING (DIGITAL PANEL 96x48 – BACK DIMENSION 86x40.5)
41 [mm] H=55+CONNECTION [mm]
87 [mm]
TOP VIEW TERMOREGULATOR 60 AMPERE + 90 AMPERE

AND HOLES FOR PANEL MOUNTING
Nr. 3 HOLES D=4,5 mm
120 [mm] 95 [mm] H=145 [mm]
82[mm]
20 [mm]
100 [mm]
TOP VIEW TERMOREGULATOR 90 AMPERE (OBSOLETE)

AND HOLES FOR PANEL MOUNTING
Nr. 2 HOLES D=4,5 mm
180 [mm] 168 [mm] H=145 [mm]
100 [mm]

ANNEX F – MULTIVOLTAGE TRANSFORMER TECHNICAL FEATURES
TRANSFORMER 1400VA/70V/30A CODE: 3ESD0063
Impulsive Transformer for thermoregulator 30A
0 / 230 / 400 / SCH / GND = 0 / 30 / 40 / 50 / 60 / 70
DESCRIPTION
REFERENCE NORM: CEI 96-2 EN60742 “Insulation and safety transformers”
TRASFORMER IN CLASS I
MONOPHASE
PROTECTION RATIO: IP20
COOLING: Natural air
FEATURES
RATED POWER: 1400 VA
FREQUENCY: 50….60 Hz
MAINS SUPPLY: 230 – 400 Monophase
ACTIVE MAINS CURRENT: 6,1 – 3,5 A
OUTPUT VOLTAGE: 30 – 40 – 50 – 60 – 70 V Monophase
ACTIVE OUTPUT CURRENT: 30 A
OUTPUT UNLOAD VOLTAGE : 31 – 41.3 – 51.6 – 64.8 – 76.8 V c.d.t. at rated power : 5.4%
ISTANTANEUS APPARENT POWER: 2.1 the rated power
(Supplied for a short time with c.d.t. 5% e cosφ= 0.5)
PRIMARY PROTECTION: “D” type circuit braker with In = active supply current
THERMIC CLASS: F
INSULANCE CLASS MATERIALS: F
MAXIMUM AMBIENT TEMPERATURE: 40°C
VACUUM TEST: cosφ0 = 0.11 P0 = 18 W I0 = 0.4 A +/- 30% a 230 V
SHORT CIRCUIT TEST: cosφcc = 0.94 Pcc = 75 W Vcc% = 5.7%
ADDITIONAL LEAKAGE: Padd = 10 W
TOTAL LEAKAGE: Pp = Pcc + P0 + Padd = 103 W
EFFICENCY A cosφ = 1: η = 92.5%
MATERIAL CHARACTERISTIC
SUPPORT BY INSULANCE MATERIAL: Class “F”
COILS IN COPPER, GRADE 2: Classe “H”
PROTECTION OF THE OUTPUTS WIRES: class “H”
(electric strength 4 KV)
OUTPUTS TERMINALS: (IP20)
INSULANCE TREATMENT: Impregnating by insulance paint auto-extinguishing type BC359/D green Class “F”
DRYING: oven-drying of the insulance paints , after treatment

TRANSFORMER 3000VA/50V/60A SERV. 40% CODE: 3ESD0064
Impulsive Transformer for thermoregulator 60A
0 / 230 / 400 / SCH / GND = 0 / 30 / 40 / 50
DESCRIPTION
REFERENCE NORM: CEI 96-2 EN60742 “Insulation and safety transformers”
TRASFORMER IN CLASS I
MONOPHASE
PROTECTION RATIO: IP20
COOLING: Natural air
FEATURES
RATED POWER: 3000 VA Serv. 40%
FREQUENCY: 50….60 Hz
MAINS SUPPLY: 230 – 400 Monophase
ACTIVE MAINS CURRENT: 6,1 – 3,5 A
OUTPUT VOLTAGE: 30 – 40 – 50 V Monophase
ACTIVE OUTPUT CURRENT: 60 A
OUTPUT UNLOAD VOLTAGE : 31 – 41.3 – 51.6 – 64.8 – 76.8 V c.d.t. at rated power : 5.4%
ISTANTANEUS APPARENT POWER: 2.1 the rated power
(Supplied for a short time with c.d.t. 5% e cosφ= 0.5)
PRIMARY PROTECTION: “D” type circuit braker with In = active supply current
THERMIC CLASS: F
INSULANCE CLASS MATERIALS: F
MAXIMUM AMBIENT TEMPERATURE: 40°C
VACUUM TEST: cosφ0 = 0.11 P0 = 18 W I0 = 0.4 A +/- 30% a 230 V
SHORT CIRCUIT TEST: cosφcc = 0.94 Pcc = 75 W Vcc% = 5.7%
ADDITIONAL LEAKAGE: Padd = 10 W
TOTAL LEAKAGE: Pp = Pcc + P0 + Padd = 103 W
EFFICENCY A cosφ = 1: η = 92.5%
MATERIAL CHARACTERISTIC
SUPPORT BY INSULANCE MATERIAL: Class “F”
COILS IN COPPER, GRADE 2: Classe “H”
PROTECTION OF THE OUTPUTS WIRES: class “H”
(electric strength 4 KV)
OUTPUTS TERMINALS: (IP20)
INSULANCE TREATMENT: Impregnating by insulance paint auto-extinguishing type BC359/D green Class “F”
DRYING: oven-drying of the insulance paints , after treatment

ANNEX G – START UP CARD – PAG. 1
COMMERCIAL NOTE
MODEL OF MACHINE:
CUSTOMER:
BAND POSITION:
KIND OF FILM TO SEAL:
THICKNESS OF FILM TO SEAL:
APPLICATION NOTE
Band material = _______________________
Band form profile = _______________________
Width of the band = _______________________ [mm]
Thickness of the band = _______________________ [mm]
Length overall = _______________________ [mm]
Copper/Silver ends = _______________________ [2 x mm]
Copper/Silver in the centre = _______________________ [mm]
Teflon coat in the centre = _______________________ [mm]
Type of connections (Parallel/Serial) = _______________________ [P/S]
TECNICHAL NOTE
SECTION OF THE SEALING BAND = _______________________ [square mm]
RESISTANCE OF THE SEALING BAND = _______________________ [Ω]
HEATING CURRENT CALCULATED = _______________________ [60/90/120 A]
SECONDARY VOLTAGE OF THE TRANSFORMER = ______________________ [V]
MODEL OF THE THERMOSALD ISC = _______________________
PRIMARY SECONDARY
LOW VOLT
RATED CURRENT 60 90 120
PRE-HEAT TEMPERATURE = _____________ [°C]

SEALING TEMPERATURE = _____________ [°C]
SEALING TIME (SET INTO THE PLC) = _____________ [Sec.]

ANNEX G – START UP CARD – PAG. 2
MACHINE DATA TABLE Default
RATED CURRENT 1 [ xxx ] : 1
HEATING INCREASE DEGREE 2 [4] : 2
PROPORZION.GAIN KV 3 [ 100 ] : 3
INTEGRAL GAIN KI 4 [ 100 ] : 4
OPERATING LIMIT KI 5 [ 60 ] : 5
DERIVATIV GAIN KD 6 [ 40 ] : 6
HEATING FACTOR 7 [ 1.9 ] : 7
INITIAL TEMPERATURE 8 [0] : 8
PARTIAL SHORT CIRC.FACT. 9 [ 1.2 ] : 9
ALLARM DISABLE 10 [0] : 10
CONFIG. IMPULSE SEAL 11 [0] : 11
CONFIG. PANEL 12 [2] : 12
CONFIG.SER. RS485(1=9600) 13 [1] : 13
ADDRESS SERIAL RS485 14 [1] : 14
SETTING DATA TABLE Default

LANGUAGE SELECTION 0 [ITAL.IAN] : 0
DEGREES SELECTION 1 [ CELSIUS ] : 1
CALIBRATING TEMPERAT. 2 [ 30 ] : 2
MAX SEALING TEMPER.AT. 3 [ 250 ] : 3
MAX SSEALING TIME 4 [ 0.0 ] : 4
BURN IN DEGREES 5 [ 180 ] : 5
BURN IN SECONDS 6 [ 05 ] : 6
BURN IN NR. CYCLES 7 [ 05 ] : 7
TEMPERATURE GRADIENT 8 [4 ] : 8
ENABLE COMP.WITH COLD 9 [0] : 9
SEAL TEMPER. WITH COLD 10 [ 220] : 10
STRUCTURE TEMPERATURE 11 [ 80 ] : 11
TIME WARN66 12 [3] : 12
PAR.1=ODD,2=EVEN 13 [0] : 13
NR.STOP BIT 14 [2] : 14
PROTOCOL TIME OUT 15 [ 0.1 ] : 15
IDLE CHAR BEFORE TX 16 [0] : 16
CHECK 1=CRC,2=XOR,0=NO 17 [1] : 17


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TEMPERATURE CONTROLLER FOR IMPULSE SEALING

MAINTENANCE & OPERATIONS MANUAL

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

0.1 SAFETY PRECAUTIONS

- Never use the equipment in explosive atmospheres or with explosive materials.

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

TESTS AND RESULTS:

THE PRODUCT IS COMPLIANCE TO ABOVE MENTIONED NORMES EMC in accord to DIRECTIVE

THE PRODUCT IS COMPLIANCE TO LOW VOLTAGE NORME in accord to DIRECTIVE 73/23/CEE,

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

- MANUAL COD. 3ES080x_Vx_CO_EN - COMMERCIAL CATALOGUE

- MANUALE COD. 3ES080x_Vx_QS_FR - QUICK START MANUAL

If requested It will be possible to edit specific language.

ALL MANUALS ARE AVALIABLE ON OUR INTERNET WEB SITE:

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

CN1 POWER TERMINAL BLOCK (SWITCH ON SECONDARY)

CN1 POWER TERMINAL BLOCK (SWITCH ON PRIMARY)

CN2 CONTROL CIRCUIT SUPPLY TERMINAL BLOCK

CN3 CONTROLS TERMINAL BLOCK

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

CN5 RS 485 SERIAL INTERFACE CONNECTOR (9 PIN FEMALE)

CN6 REFERENCE TERMINAL BLOCK

CN7 POTENTIOMETER CONNECTOR (9 PIN MALE)

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

3.1 – ANALYSIS OF APPLICATION

BEFORE BEGINNING THE FIRST INSTALLATION, READ CAREFULLY THE

IT IS ENOUGH FOLLOW STEP TO STEP THE FOLLOWING INSTRUCTIONS TO START

• WHICH BAND CAN USE TO HAVE THE MAXIMUM?

• Chamfered (tapered edge) …………………….

• Width: LARG= ……………………. [mm]

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

Usable length: L-UTIL = ……………………. [mm]

• CALCULATION OF THE BAND SECTION

Section: SEZ = ……………………. [mmq]

3.2 - CALCULATION OF SEALING BAND RESISTANCE

1– single band = R-BAND = R0 x L-UTIL [ mt. ]

R0 = Specific resistance of the band [ Ω / mt ]

Resistance: R-BAND= ……………………. [Ω]

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

• WHAT TYPE OF THERMOREGULATOR IS TO CHOOSE ?

It depends from the HEATING CURRENT as following:

I HEATING =BAND SECTION S[square mm] x 30[Amp/squaremm]

The thermoregulator must have a nominal current more then I HEATING.

CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD

CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD

CONFIGURATION SINGLE SECTION I HEATING I THERMOSALD

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

• WHICH TRANSFORMER IS TO CHOOSE?

• WHICH VALUE OF SECONDARY VOLTAGE?

Transforer: POWER = ……………………. [ VA ]

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

• WHICH PROTECTIVE DEVICES ARE TO CHOOSE? (MODULATION ON THE SECONDARY)

• WHICH PROTECTIVE DEVICES ARE TO CHOOSE? (MODULATION ON THE PRIMARY)

THERMOSALD ISC – MAINTENANCE & OPERATIONS MANUAL Rev. 2010 / 03

• WHICH ACTIONS ARE TO DO, TO HAVN’T PROBLEMS DURING STARTING UP?

Use original power transformers by 3E