RESISTRON

RES-5027

Operating
Instructions

Important features

• Automatic zeroing (AUTOCAL)

• Automatic optimisation (AUTOTUNE)
• Automatic configuration of the secondary voltage and current range (AUTORANGE)
• Automatic phase correction (AUTOCOMP)
• Automatic frequency adaptation
• Booster output
• Temperature OK output
• Analogue input for setpoint specification with potentiometer or 0…10 VDC
• Analogue output 0…10 VDC for ACTUAL temperature
• 24 VDC control signals for START, AUTOCAL, RESET and CH-1, e.g. constant setting degree
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected
• Wide voltage range for the use of 110…480 V

• Micro-USB interface for ROPEXvisual®

• cULus approval
Version 3
01.12.2021

ROPEX Industrie-Elektronik GmbH Tel.: +49 (0)7142-7776-0 E-Mail: [email protected]

Adolf-Heim-Str. 4 Fax: +49 (0)7142-7776-211 Internet: https://ropex.de
74321 Bietigheim-Bissingen (Germany) Data subject to change
Contents
1 Revision list . . . . . . . . . . . . . . . . . . . . . . . . . 3 8 Device functions . . . . . . . . . . . . . . . . . . . . 20
2 General information .................. 3 8.1 Display and operating elements . . . . 20
2.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 3 8.2 Temperature setting (setpoint
specification) . . . . . . . . . . . . . . . . . . . 21
2.2 Intended use . . . . . . . . . . . . . . . . . . . . 3
8.3 Temperature display (actual value
2.3 Heatsealing band ................ 3
output) . . . . . . . . . . . . . . . . . . . . . . . . 22
2.4 Impulse transformer .............. 4
8.4 Autom. zeroing (AUTOCAL) . . . . . . . 23
2.5 Current transformer PEX-W4/-W5 . . . . 4
8.5 START signal (HEAT) . . . . . . . . . . . . 24
2.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 4
8.6 RESET signal . . . . . . . . . . . . . . . . . . 25
2.7 Maintenance . . . . . . . . . . . . . . . . . . . . 5
8.7 CH-1 signal . . . . . . . . . . . . . . . . . . . . 26
2.8 Transportation . . . . . . . . . . . . . . . . . . . 5
8.8 TCR Calculator . . . . . . . . . . . . . . . . . 26
2.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5
8.9 Measurement impulse duration . . . . . 28
2.10 DECLARATION OF CONFORMITY . . 6
8.10 Automatic phase correction
3 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 (AUTOCOMP) . . . . . . . . . . . . . . . . . . 28
4 Functional principle .................. 7 8.11 Temperature diagnosis . . . . . . . . . . . 30
8.12 “Temperature reached” or “Temperature
5 Controller features ................... 7
OK” signal . . . . . . . . . . . . . . . . . . . . . 31
6 Mounting and Installation . . . . . . . . . . . . . . 8 8.13 Heat-up time monitoring . . . . . . . . . . 33
6.1 Installation sequence . . . . . . . . . . . . . . 8 8.14 Restart delay after Reset . . . . . . . . . . 34
6.2 Installation notes . . . . . . . . . . . . . . . . 10
8.15 Maximum measurement pause . . . . . 34
6.3 Power supply . . . . . . . . . . . . . . . . . . . 11 8.16 Booster connection . . . . . . . . . . . . . . 35
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 12 8.17 USB interface for visualisation software
6.5 Current transformer PEX-W4/-W5 . . . 12 ROPEXvisual® . . . . . . . . . . . . . . . . . . . . . . . 35
6.6 Supply voltage . . . . . . . . . . . . . . . . . . 14 8.18 AUX interface . . . . . . . . . . . . . . . . . . 35
6.7 Connection diagram (standard) . . . . . 14 8.19 Data storage for error messages and
6.8 Connection diagram with booster AUTOCAL . . . . . . . . . . . . . . . . . . . . . 36
connection . . . . . . . . . . . . . . . . . . . . . 15 8.20 Integrated clock (date and time) . . . . 36
7 Commissioning and operation . . . . . . . . . 16 8.21 System monitoring/alarm output . . . . 36
7.1 Device view . . . . . . . . . . . . . . . . . . . . 16 8.22 Error messages . . . . . . . . . . . . . . . . . 37
7.2 Device configuration . . . . . . . . . . . . . 16 8.23 Error ranges and causes . . . . . . . . . . 41
7.3 Changing and burning in the heating 9 Factory settings . . . . . . . . . . . . . . . . . . . . . 42
element . . . . . . . . . . . . . . . . . . . . . . . 17
10 Technical data . . . . . . . . . . . . . . . . . . . . . . 44
7.4 Commissioning rules . . . . . . . . . . . . . 18
11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 46
12 Modifications (MODs) . . . . . . . . . . . . . . . . 46
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 47
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Page 2 RES-5027 Version 3

Revision list

1 Revision list

Version Change

1 • Creation of documentation

2 • New: section 8.8 "TCR Calculator" on page 26

• New: section 8.14 "Restart delay after Reset" on page 34
• New: section 8.15 "Maximum measurement pause" on page 34

3 • Addition: list „The AUTOCAL function is blocked:“

section 8.4 "Autom. zeroing (AUTOCAL)" on page 23
• Distinction: 24 V supply inrush current and control mode
section 10 "Technical data" on page 44

2 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.

2.1 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.

2.2 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.

2.3 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.

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 General information

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.

2.4 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.

2.5 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.

2.6 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 2.10 "DECLARATION OF CONFORMITY" on page 6. This device must be installed and connected
according to the instructions contained in section "Power supply" as well as the separate documentation enclosed
with the line filter.

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General information

2.7 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.

2.8 Transportation

Store and transport the device in its original carton.

After transport, perform a visual inspection for possible damage.

2.9 Disposal

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

This device must not be disposed of as residual waste!

!

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 General information

2.10 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/CIRUS temperature controller with accessories

Type: With line filter and current transformer

Operating principle: Impulse sealing of films and plastics

Compliant with following standards and directives:

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

2014/35/EU Low voltage directive

2014/30/EU Electromagnetic compatibility directive

2011/65/EU RoHS directive

Note:

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

Comments:

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

July 12, 2020

J. Kühner (CEO)

ROPEX Industrie-Elektronik GmbH

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

Page 6 RES-5027 Version 3

Use

3 Use
This RESISTRON® temperature controller is part of the “Series 5000”, whose main characteristic is micropro-
cessor technology. All RESISTRON® temperature controllers provide temperature regulation of heating elements
as are used in a variety of foil sealing processes.
The most common heating elements include:
• ribbon cables (straight and contoured)
• clincher bands
• beaded bands
• cutting wires
• heat-sealing blades
• soldering bows
The main application area is sealing or cutting of thermoplastics using the thermal impulse process.
The most common application areas are:
• vertical and horizontal form-fill-seal machines (VFFS and HFFS)
• bagging, filling and sealing machines
• film-wrapping machines
• bag-production machines
• group packaging machines
• foil sealing devices
• spout and hose sealing
• and much more

4 Functional principle
The resistance of the heating element, which changes with temperature, is measured by means of current and
voltage measurement, displayed and compared with the specified setpoint value. Measurements are made
50 times per second in a 50 Hz network, 60 times per second in a 60 Hz network.
The primary voltage of the impulse transformer is adjusted following the leading edge principle if the measured
values deviate from the setpoint value. The related current change in the heating element results in a rise in tem-
perature and change of resistance. The change in resistance is measured and evaluated by the RES-5027. The
temperature controller adjusts the control variables according to the change and the set setpoint.
Even the smallest thermal loads on the heating element are recorded and can be quickly and precisely corrected.
Measurement of pure electric variables, together with the high measurement rate, result in a highly dynamic ther-
moelectric control circuit. The principle of primary-side transformer control proves to be especially advantageous
as it permits a very large secondary current range with low power loss. This permits an optimal adjustment to the
load and thus the desired dynamics with extremely compact device measurements.

5 Controller features
The analogue interfaces for temperature setpoint and temperature actual value 0…10 VDC, which are electrically
isolated from the heating circuit, permit temperature setting directly from the machine control or also through an
external potentiometer (PD-x).

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 Mounting and Installation

The real heating element temperature can also be visualised on a machine controller display or an external display
instrument (ATR-x).
The RESISTRON® temperature controller RES-5027 has an integrated error diagnosis that checks both the
external system (heating element, wiring, etc.) and the internal electronics and puts out a differentiated error mes-
sage in case of malfunction.
To increase operational security and immunity to interference, all 24 VDC logic signals and 0-10 VDC analogue
signals are electrically isolated from the heating circuit.
Adjustment for different heating element alloys (alloy A20, etc.) and setting of the temperature range to be used
(0…300°C, 0…500°C, etc.) can be performed through coding switches on the temperature controller itself.
An external voltage supply of 24 VDC is required for the controller. The compact design of the RESISTRON® tem-
perature controller RES-5027 as well as the plug-in connecting terminals make mounting and installation easier.
An overview of the most important features and functions:
• Easy calibration of the heating element through AUTOCAL, the automatic zero-point setting
• High control dynamics through AUTOTUNE, automatic adjustment to the controlled system
• High flexibility: A secondary voltage range of 0.4 V to 120 V and a current range of 30 A to 500 A are covered
through the AUTORANGE function
• Automatic adjustment to the network frequency in the range of 47 Hz to 63 Hz
• Wide voltage range for flexible use from 110 VAC to 480 VAC
• Easy and convenient system diagnosis and process visualisation through the free, downloadable software
ROPEXvisual®
• Error diagnosis
• Booster output available for connecting a switching amplifier

6 Mounting and Installation

 See also section 2 "General information" on page 3.

Mounting, installation and commissioning may only be performed by qualified and trained persons
! who are familiar with the related hazards and warranty stipulations.

The supply voltage to the machine side must lie within the permitted voltage and frequency range
! of the RESISTRON® temperature controller. Otherwise, there is the danger of a defect.

6.1 Installation sequence

Proceed as follows during mounting and installation of the RESISTRON® temperature controller RES-5027:
1. Switch off network voltage; verify that no voltage is present.
2. Mounting of the RESISTRON® temperature controller in the switching cabinet on a TS35 top hat rail (in accord-
ance with DIN EN 50022). If several devices are mounted, the minimum distance specified in section 10 "Tech-
nical data" on page 44 must be maintained.
3. Wiring of the system in accordance with the regulations in section 6.3 "Power supply" on page 11, section 6.6
"Supply voltage" on page 14 and the ROPEX Application Report. The specifications in section 6.2 "Installation
notes" on page 10 must also be observed.
Cables that are connected to control or measurement connections may only run within the building.
4. During installation, an overcurrent protection device with max. 10 A must be provided, e.g.:
- circuit breaker in accordance with EN 60898 (characteristic B, C, D, K or Z)
- circuit breaker in accordance with UL489 (*) (characteristic B, C, D, K or Z)

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Mounting and Installation

- protective fuse gG in accordance with IEC 60269

- protective fuse “Class CC” or “Class J” in accordance with UL 248 (*)

The overcurrent protective devices marked with (*) must be used in installations falling under the UL regula-
tions.

If this overcurrent protective device is not sufficient for the sealing application, two separate overcurrent pro-
tective devices must be provided for the controller and the sealing application ( ROPEX application report).
The overcurrent protective device must be located in the immediate vicinity of the device.
In the ROPEX application report, the smallest possible specification for this overcurrent protective device is
specified based on the calculated currents. If the protective device is dimensioned differently, the current car-
rying capacity of the components used (e.g. cable, impulse transformer, etc.) must be adjusted accordingly.
5. A disconnect device, which must be marked as belonging to the system and attached in an easily reachable
position, must be provided In the installation.
If a circuit breaker is used, it can take over the function of the disconnect device.

Check all connection terminals of the system – including the terminals for the coil wires on the
! impulse transformer – that they are seated firmly.

6. Check the wiring in accordance with the applicable national and international installation and setup stipulations.

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 Mounting and Installation

6.2 Installation notes

Sample depiction

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-W4 / W5 Current measuring
U1 (prim.) wires IR
U2 (sec.)
Line
Line filter
Avoid long LF-xxxxx
cables

Impulse
transformer
Dimension
transformer correctly
- Secondary voltage
- Power 20 mm clearance if several
- Duty cycle controllers installed on
one top hat rail

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Mounting and Installation

6.3 Power supply

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

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

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

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 Mounting and Installation

6.4 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 6.3 "Power supply" on page 11 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

6.5 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 6.3 "Power supply" on page 11).

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Mounting and Installation

6.5.1 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 (EN 60715)

6.5.2 PEX-W5

Mounting on DIN-rail 35 x 7.5 mm or 35 x 15 mm (EN 60715).

If the high-current wire cannot be routed through the opening provided, an HCB-1 high-current rail must be used.

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 Mounting and Installation

6.6 Supply voltage

To provide power to the RES-5027, voltage of 24 VDC must be applied to the terminals 12+13. The maximum cur-
rent draw is 1.0 A. The supply voltage input is protected against faulty polarisation.

6.7 Connection diagram (standard)

Line filter
1
RES-5027 LINE
(also with MOD 01) 2
AUTOCAL
24 VDC signal 5

22
START (HEAT) BOOSTER
24 VDC signal 6 21

RESET
24 VDC signal 7 3

4
CH-1 U1
24 VDC signal 20
prim.
Impulse
transformer
PE 14
U2
Protective con- sec.
ductor connection

GND 13 8 Heat-
UR R sealing
24 VDC POWER 9 band
SUPPLY twisted
+24 VDC 12

ANALOG INPUT
(setpoint) 16 10
+0...10 VDC IR
11
ANALOG OUTPUT Current transformer
(actual value) 17
+0...10 VDC

ALARM OUTPUT
18
+24 VDC

TEMP. OK
OUTPUT 19
+24 VDC
REFERENCE
VOLTAGE =
15
OUTPUT UREF =
+10 VDC

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Mounting and Installation

6.8 Connection diagram with booster connection

Line filter
1
RES-5027 LINE
(also with MOD 01) 2
AUTOCAL
24VDC signal 5 Booster
3 1
22
IN OUT
START (HEAT)
24 VDC signal 6 21
4 2
twisted
Max. length 1 m
RESET
24 VDC signal 7 3

4
CH-1 U1
24 VDC signal 20
prim.
Impulse
transformer
PE 14
U2
Protective con- sec.
ductor connection

GND 13 8 Heat-
UR R sealing
24 VDC POWER 9 band
SUPPLY twisted
+24 VDC 12

ANALOG INPUT
(setpoint) 16 10
+0...10 VDC IR
11
ANALOG OUTPUT Current transformer
(actual value) 17
+0...10 VDC

ALARM OUTPUT
18
+24 VDC

TEMP. OK
OUTPUT 19
+24 VDC
REFERENCE
VOLTAGE =
15
OUTPUT UREF =
+10 VDC

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 Commissioning and operation

7 Commissioning and operation

7.1 Device view

Display LEDs

Coding and
slide switch

USB interface Terminal plan

Rating plate

Connection terminals

7.2 Device configuration

The controller must be switched off to configure the coding switch of the slide switch.
!
7.2.1 Configuration for secondary voltage and current
The ranges for secondary voltage and current are configured automatically when automatic calibration
(AUTOCAL) is carried out. Configuration takes place in the voltage range of 0.4 VAC to 120 VAC and in the current
range from 30 A to 500 A. If voltage and/or current is outside the allowed range, a detailed error message is output
by the controller ( see section 8.22 "Error messages" on page 37).
For secondary currents I2 less than 30 A, the secondary high-current line must be guided 2 times (or several times)
through the transformer PEX-W4 or PEX-W5 ( ROPEX application report).

2x

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Commissioning and operation

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

Switch Temp. Temp. Band

position range coefficient alloy
ALARM OUTPUT DE- ENERGIZED
0 300°C 1100ppm/K e.g. A20 CONFIGURATION
(AT ALARM)

1 300°C 780ppm/K e.g. L

ENERGIZED

4 500°C 1100ppm/K e.g. A20

5 500°C 780ppm/K e.g. L

AUX
PC CONFIGURATION 9
8 300°C 3500ppm/K 3500ppm/K
780ppm/K (L)
8
5
300°C
500°C

9 PC-CONFIGURATION 0
1100ppm/K (A20)
780ppm/K (L)
4
1
500°C
300°C

1
67 9
1100ppm/K (A20) 0 300°C

2 34
8
TEMP. COEFFICIENT SWITCH POS. TEMP. RANGE
0
5

1
789

2 34
0 = Factory settings
6

This configuration is available as standard.

When the switch position “9” is selected, additional temperature ranges and alloys can be set through the ROPEX
visualisation software ( see section 8.17 "USB interface for visualisation software ROPEXvisual®" on page 35).

7.2.3 Configuration of the alarm output

Alarm output opened ALARM OUTPUT DE-ENERGIZED

(AT ALARM)
by alarm/
CONFIGURATION
ENERGIZED

PC-CONFIGURATION
Alarm output closed
AUX

by alarm.
(factory setting)
90 1
2 3
78

4 56

When the “Alarm output opens with Alarm/PC CONFIGURATION” is selected, additional configurations for the
behaviour of the alarm output can be set through the ROPEX visualisation software ( section 8.17 "USB inter-
face for visualisation software ROPEXvisual®" on page 35).

7.3 Changing and burning in the heating element

7.3.1 Burning in the heating element

The heating element is an important component in the control circuit, as it is both a heating element and sensor.
The geometry of the heating element cannot be discussed here due to its diversity. Accordingly, only some impor-
tant physical and electrical characteristics are pointed out here:
The measurement principle used here requires from the heating element alloy a suitable temperature coefficient
TCR, ie an increase in resistance with temperature. A TCR that is too small results in vibrating or overheating of
the heating element.
If the TCR is large, the controller must be calibrated for it. The RESISTRON® temperature controller is suitable for
temperature coefficients in the range 400…4000 ppm/K.
The first time it is heated to approx. 200…250 °C, the usual alloy undergoes a one-time change in resistance
(burn-in effect). The cold resistance of the heating element is reduced by about 2…3%. But this small change in

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 Commissioning and operation

resistance generates a zero point error of 20…30 °C. The zero point must therefore be corrected after a few
heating cycles, that is, the AUTOCAL function must be carried out again.
The burn-in effect described here does not need to be considered if the manufacturer pretreated the heating ele-
ment for this purpose.

A damaged or worn-out heating element may no longer be used due to an irreversible TCR change.
!
A very important design measure is copper-coating or silver-coating of the heating element ends. The thermal
characteristics change in this range through coating of the heating element ends. As a result, the ends remain
cold, which permits exact temperature control and increases the useful life of the heating element.

7.3.2 Changing the heating element

To change the heating element, the supply voltage must be disconnected from the RESISTRON®
! temperature controller on all pins.

The heating element must be changed in accordance with the manufacturer’s instructions.
!
After every heating element change, the AUTOCAL function must be performed with a cold heating element (and
cold surroundings: i.e. silicone, PTFE cover, sealing bar, among others) to compensate for production-related tol-
erances of the heating element resistance. With a new heating element, the above-described procedure for
burning in must be performed.

7.4 Commissioning rules

Observe here section 2 "General information" on page 3 and section 3 "Use" on page 7.

Mounting, installation and commissioning may only be performed by qualified and trained persons
! who are familiar with the related hazards and warranty stipulations.

7.4.1 Initial startup

Requirement: Device is correctly mounted and connected ( section 6 "Mounting and Installation" on page 8).
Proceed as follows when starting up the controller for the first time:
1. Switch off network voltage; verify that no voltage is present.
2. Set the coding switch on the device in accordance with the ROPEX application report and the heating element
used (section 7.2 "Device configuration" on page 16).
3. Check that there is no START signal present.
4. Apply auxiliary voltage (24 VDC).
5. Switching on the network voltage.
6. After the voltage is switched on, the yellow “AUTOCAL” LED lights up for about 0.3 sec. and displays the cor-
rect switch-on process of the controller. As long as no network voltage is present, this LED flashes slowly
(1 Hz).

At switch-on, if in addition to the yellow “AUTOCAL” LED the red “ALARM” LED lights up for
! 0.3 sec, the configuration with the visualisation software has been changed for this controller
( section 8.17 "USB interface for visualisation software ROPEXvisual®" on page 35). The controller’s
configuration must be checked to avoid malfunctions before continuing with commissioning.

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Commissioning and operation

7. The following statuses can then result:

“ALARM” LED “OUTPUT” LED MEASURE

OFF Short pulses every 1.2 sec. Continue with item 8

FLASHES quickly (4 Hz) OFF Continue with item 8

Permanently ON OFF Error diagnosis ( Chap. 8.22)

8. With a cold heating element, activate the AUTOCAL function (terminal 5+13). The yellow “AUTOCAL” LED
lights up for the duration of the calibration process (approx. 10…15 seconds). During this process, a voltage of
approx. 0 V is output at the actual value output (terminal 17+13). A connected ATR-x shows 0…3 °C.
After zeroing is completed, the “AUTOCAL” LED goes out, and a voltage of 0.66 V (in 300 °C range) or 0.4 V
(in 500 °C range) is set at the actual value output. A connected ATR x must be on the “Z” marking.
If zeroing was not performed correctly, the red “ALARM” LED flashes slowly (1 Hz). Then configuration of the
controller is not correct ( section 7.2 "Device configuration" on page 16, ROPEX application report). After
device configuration is correct, perform zeroing again.
9. After successful zeroing, specify a defined temperature at the setpoint value input (terminal 16) and apply the
START signal (HEAT). “HEAT” LED then lights up. The heat-up and control procedure can be observed at the
actual value output:
It is functioning correctly when the temperature (i.e. signal change at the analogue output) is steady, that is,
does not jump, oscillate or even go briefly in the wrong direction. Such behaviour indicates an incorrect place-
ment of the UR measurement line.
When an error message is issued, proceed according to section 8.22 "Error messages" on page 37.
10.Burning in the heating element ( section 7.3.1 "Burning in the heating element" on page 17) and repeat
AUTOCAL function.

7.4.2 Placing back into operation after changing the heating element
When changing the heating element, proceed according to section 7.3.1 "Burning in the heating element" on
page 17.

Pay attention to correct alloys, dimensions and copper coating of the new heating element to avoid
! malfunctions and overheating.

Continue with chap. 7.4.1 item 3 to item 10.

Version 3 RES-5027 Page 19

 Device functions

8 Device functions
See also section 6.6 "Supply voltage" on page 14.

8.1 Display and operating elements

AUTOCAL Lit while AUTOCAL process is

(Yellow LED) executing.
OUTPUT Indicates pulses in
(Green LED) measurement mode. In control
mode, luminous intensity is
proportional to heating current.
HEAT Lit during heating phase.
(Yellow LED)
ALARM Lit or blinking to indicate fault.
(Red LED)
19 20 21 22 12 13 14 15 16 17 18

Vi s u a l
CH-1 Lit if the input signal CH-1 is
AUTOCAL
(Yellow LED) active. OUTPUT
HEAT
ALARM
CH-1
TEMP. OK Lit if the actual temperature is TEMP. OK
µC POWER
(Green LED) within the monitoring band. 24 V POWER
5 6 7 8 9 10 11

µC POWER Lit if internal µC power supply !

(Green LED) is OK. RES-5027
PROCESS CONTROL
EQUIPMENT
24 V POWER Lit if external 24 V power E464680
www.ROPEX.de
(Green LED) supply is present. 1 2 3 4 Made in Germany

The LEDs display additional operating statuses of the controller besides the functions in the above illustration.
These are shown in detail in the following table:

LED Flashes slowly (1 Hz) Flashes quickly (4 Hz) On permanently

RESET active,
AUTOCAL AUTOCAL requested, but
START and AUTOCAL AUTOCAL is carried out
(yellow) function is blocked.
function are blocked.

HEAT HEAT requested,

— START is carried out
(yellow) But function is blocked

OUTPUT
In control operation, the light intensity is proportional to the heating current.
(green)

Controller incorrectly cali-

ALARM Configuration error,
brated, carry out Error,  chap. 8.22
(red) AUTOCAL not possible
AUTOCAL

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Device functions

LED Flashes slowly (1 Hz) Flashes quickly (4 Hz) On permanently

CH-1 CH-1 function requested,

— CH-1 function is carried out
(yellow) but function is blocked

Temperature lies in the

temperature monitoring
TEMP. OK band
— —
(green) or:
Actual value has achieved
95% of the setpoint value

µC POWER Voltage supply to the

— —
(green) micro-controller is present

24 V voltage supply is
24 V POWER — —
present

8.2 Temperature setting (setpoint specification)

The welding temperature can be set in the RES-5027 in two ways:

• Through application of a voltage 0…10 VDC at the terminal analogue input 16 + 13:

RES-5027

+ 16

0…10 VDC
- 13
GND

The correlation between the applied voltage and the ACTUAL temperature is linear.
Setting range:
0 VDC  0 °C
10VDC  300 °C or 500 °C, Depending on the device configuration
A corresponding diagram is depicted in section 8.3 "Temperature display (actual value output)" on page 22.

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 Device functions

• Through connection of a 2 kOhm potentiometer at the terminals 13…16:

RES-5027 Potentiometer with

Digital button PD-x

15 UREF 10 VDC
CW 15
2K 16 IN 0…10 VDC 3
13
1
13 2
16
14
PE

To be able to specify the setpoint with a potentiometer, the controller provides a reference voltage of +10 VDC
(± 5% at terminal 15.
The correlation between potentiometer setting and the SETPOINT temperature is linear.
The connection line between controller and potentiometer must be screened.
When the ROPEX precision potentiometer PD-x (PD-03 for 300 °C or PD-05 for 500 °C) is used, the set SET-
POINT temperature can be set exactly with the help of the numbers in the viewing window of the fine drive button.
The set number equals the SETPOINT temperature in °C.
The setpoint specification for the welding temperature must be greater than 40 °C. If it is less, no heating process
takes place when the START signal is activated.

Setpoint value zero applies if the potentiometer is not connected or 0 VDC is applied at the setpoint
! value input. Pay attention to the direction of rotation when connecting the potentiometer!

8.3 Temperature display (actual value output)

The RES-5027 sends to the terminals 17+13 an analogue signal 0…10 VDC, which is proportional to the real
ACTUAL temperature.

RES-5027
Actual value- Max. 5 mA
Output 17
0…10 VDC
GND
13
0V
0…10 VDC
- +
Temperature
display
e.g. ATR-x

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

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Device functions

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

°C 0 - 300 °C range °C 0 - 500 °C range

300 500
Temperature T

Temperature T
270 450
240 400
210 350
180 300
150 250
120 200
90 150
60 100

20 ºC 20 ºC
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10
0.66 V Voltage U VDC 0 .4 V Voltage U VDC
“ZERO“ “ZERO“

A display instrument can be attached to this output for visualisation of the heating element temperature.
The ROPEX temperature display ATR-x in its overall characteristics (size, scaling, dynamic behaviour) is optimally
suited for this use and can be used for this, if needed ( section 13 "How to order" on page 47).
With this display, not only can TARGET-ACTUAL comparisons be made, but other criteria can be evaluated, such
as heat-up speed, reaching the setpoint in the specified time, cooling of the heating element, etc.
Beyond that, malfunctions in the control circuit (loose connections, contacting and wiring problems) and possibly
network faults can be observed very well at the display instrument and interpreted accordingly. This applies also
for mutual influencing of several neighbouring control circuits.
In case of alarm, this analogue output is used to output differentiated error messages ( section 8.22 "Error mes-
sages" on page 37).

8.4 Autom. zeroing (AUTOCAL)

Due to automatic zeroing (AUTOCAL), manual zero point setting at the controller is not necessary. With the
AUTOCAL function, the controller adapts to the current and voltage symbols present in the system. In the factory
setting, zeroing is carried out at the basic temperature of 20 °C.

Perform the AUTOCAL function only when heating element and support rail have cooled off (basic
! temperature).

Variable basic temperature:

The basic temperature for the AUTOCAL function can be set in the range of 0…+40 °C with the visualisation soft-
ware ( section 8.17 "USB interface for visualisation software ROPEXvisual®" on page 35). This setting is main-
tained even after the controller is switched off and on.
Moreover, the “External calibration temperature” can be selected through the visualisation software. With this set-
ting, the basic temperature is specified through the analogue input (terminal 16+13) in the range +3…+40 °C
( section 8.2 "Temperature setting (setpoint specification)" on page 21). The specification value at the analogue
input must be present when the AUTOCAL function is activated. If too high of a temperature (greater than 40 °C)
or a fluctuating specification value is specified, a corresponding error message is output (error no.115 and 116;
 section 8.22 "Error messages" on page 37).

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 Device functions

The AUTOCAL is activated through a 24 VDC pulse at terminals 5+13.

24 VDC
AUTOCAL RES-5027
+ 5
Max. 6 mA
HIGH: 12 VDC AUTOCAL

GND
- 13
LOW: 2 VDC
0.1…5 s

The automatic calibration process lasts about 10…15 seconds. The heating element is not additionally heated
during this process.
The related yellow LED on the front panel lights up when the AUTOCAL function is executed. The actual value
output (terminal 17+13) goes to 0…3 °C (i.e. approx. 0 VDC).
If the heating element temperature fluctuates, the AUTOCAL function is performed a maximum of 3x. After that, if
the function cannot be successfully ended, an error message is output (error no. 114;  section 8.22 "Error mes-
sages" on page 37).

Perform the AUTOCAL function only when heating element and support rail have cooled off (basic
! temperature).

The AUTOCAL function is blocked:

• during the first 10 seconds if the controller does not report an alarm after being switched on or reset and the
cooling speed is less than 0.1 K/s.
• if the cooling speed of the heating element is greater than 0.1 K/s.
Note:
If the AC bit is activated and the cooling speed has fallen below 0.1 K/s, the controller carries out the AUTOCAL
function.
• if the signal AUTOCAL is activated (24 V).
The "HEAT" LED lights up or blinks.
• if the signal RESET bit is activated (24 V).
• if error numbers 101 to 103, 201 to 203 or 9xx occur directly after switching on the controller. ( section 8.22
"Error messages" on page 37).
• if the controller has operated correctly at least once after being switched on and error numbers 201 to 203 or
9xx occur ( section 8.22 "Error messages" on page 37).
• if the line voltage is missing when switching on.
The "AUTOCAL" LED blinks slowly (1 Hz).
Note:
If the AUTICAL function is blocked and if there is an AUTOCAL request at the same time, the "AUTOCAL" LED
blinks quickly (4 Hz).

8.5 START signal (HEAT)

With activation of the START signal, the device-internal target-actual comparison is enabled and the heating ele-
ment is heated up to the set SETPOINT temperature. This takes place until the signal is switched off.

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Device functions

The “HEAT” LED on the front panel of the RES-5027 lights up permanently during this time.
The START signal is activated through a 24 VDC signal to the terminals 6+13.

24 VDC
START
(HEAT)
RES-5027
+ 6
max. 6 mA

HIGH: 12 VDC

GND
- 13
START (HEAT)
LOW: 2 VDC

During execution of the AUTOCAL function or when the RESET signal is active, activation of the START signal is
not accepted.
The setpoint specification for the welding temperature must be greater than 40 °C. If this is smaller, the heat-up
process is not started (LED “HEAT” flashing).
During a warning message with error no. 104…106, 111…114, 211, 302 or 303, the alarm output is switched on
when the START signal is activated ( section 8.22 "Error messages" on page 37). A heat-up procedure also
does not take place.

8.6 RESET signal

The RESISTRON® temperature controller RES-5027 can be reset through the external RESET signal
(terminal 7+13). Here:
• An ongoing welding cycle is interrupted
• No additional measurement impulses are generated
• Any error message displayed is reset
(Note: The error message is not reset until the RESET signal is switched off)

24 VDC
RESET RES-5027
+ 7
max. 6 mA
HIGH: 12 VDC RESET

GND
- 13
LOW: 2 VDC
>0.1 s

During activation of the RESET signal, the actual value output goes to 0…3 °C (i.e. approx. 0 VDC). This can be
evaluated as feedback by the higher-level controller (e.g. PLC).
Performance of the AUTOCAL function is not interrupted through activation of the RESET signal.
After the RESET signal is switched off, the controller carries out an internal initialisation for about 500 ms. The
next welding procedure can only be started after that.

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 Device functions

A fuse Kb possibly used for switching off the control circuit ( section 6.3 "Power supply" on page 11) must be
securely switched on no later than 200 ms after resetting of the RESET signal (the switching and delay times of
the fuse must be observed). Switching on later results in an alarm message from the controller.
The restart delay can be adjusted with the parameter „Restart delay after Reset“ ( section 8.14 "Restart delay
after Reset" on page 34).

8.7 CH-1 signal

With activation of the CH-1 signal, a constant power setting degree is output in the range of 5…100%. This takes
place until the signal is switched off. The “CH-1” LED on the front panel of the RES-5027 lights up permanently
during this time.
The height of the setting degree is determined through specification of the setpoint value. Here, 10 VDC corre-
spond to a setting degree of 100%.
The CH-1 signal is activated through a 24 VDC signal to the terminals 20+13.

24 VDC

CH-1
RES-5027
+ 20
max. 6 mA

HIGH: 12 VDC

GND
- 13
CH-1
LOW: 2 VDC

Activation of the CH-1 signal is not accepted during performance of the AUTOCAL function or with an active
RESET signal.
The setpoint specification for the power setting degree must be greater than 5%. If this is smaller, the heat-up
process is not started (LED “CH-1” flashes).
During a warning message with error no. 104…106, 111…114, 211, 302 or 303, the alarm output is switched on
when the CH-1 signal is activated ( section 8.22 "Error messages" on page 37). A heat-up procedure also does
not take place.

8.8 TCR Calculator

This functionality is first available as from firmware version 302.

!
The TCR Calculator can be used to determine the temperature coefficient (TCR) of the heatsealing band used.
The real temperature coefficient of the heatsealing band often differs from the standard value. The material com-
position and processing influence the properties of the heatsealing band. This leads to the fact that the tempera-
ture display of the controller differs from the real temperature of the heatsealing band. The usage of the TCR Cal-

Page 26 RES-5027 Version 3

Device functions

culator allows an easy correction of the TCR value and thus a better matching of the temperature display of the
controller and the real temperature of the heatsealing band.

The TCR Calculator can be used only with the Visualization software ( section 8.17 "USB interface
! for visualisation software ROPEXvisual®" on page 35).

To calculate the TCR value, the temperature at the heatsealing band is measured in control mode (START signal
active) using an external temperature sensor (e.g. a thermocouple). The measured temperature is transferred to
the temperature controller using the ROPEXvisual® visualization software. The calculated temperature coefficient
can be read off there. The temperature coefficient is only calculated in control mode (START signal active).
Reading back the calculated TCR value must be done during active control operation, i.e. during an active heating
impulse, as the internal measured value of the current heatsealing band temperature is used for the calculation.
Errors in the calculation of the temperature coefficient are reported with the value 0 (calculated temperature coef-
ficient too low or no active control operation) or 65535 (calculated temperature coefficient too high).
To use the TCR calculator, proceed as follows:
1. The ROPEXvisual® visualization software must be unlocked with the password 'ropex3' under 'Settings' -
'Authorize'.
2. In the 'Controller' surface, the TCR calculator is opened with the 'TCR Calculator' icon button:

3. In this surface the externally measured temperature can be entered. During an active heating process, the cal-
culated temperature coefficient is output:

4. The variable temperature coefficient is set in the 'Configuration' surface. For this purpose, the rotary coding
switch for temperature range and alloy on the RESISTRON® temperature controller RES-5027 must be set to
position 9 PC-CONFIGURATION ( section 7.2.2 "Configuration of the rotary coding switch for temperature
range and alloy" on page 17). After the temperature coefficient has been configured as 'variable', another input
field for the temperature coefficient appears. The previously calculated temperature coefficient is entered here:

5. The elements marked in blue are stored retentively in the RESISTRON® temperature controller RES-5027. The
settings are thus retained even after a device restart.

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 Device functions

8.9 Measurement impulse duration

The length of the measurement impulses generated by the controller can be set with this parameter. For certain
applications, it can be necessary to lengthen the measurement impulse beyond the standard of 1.7 ms ( ROPEX
application report).

This parameter can only be set with the ROPEX visualisation software ( section 8.17 "USB inter-
! face for visualisation software ROPEXvisual®" on page 35).

8.10 Automatic phase correction (AUTOCOMP)

In special welding applications, it may be necessary to compensate the phase displacement between the UR and
IR measurement signals ( ROPEX application report). Use of the AUTOCOMP function can be necessary here.
The AUTOCOMP function must be enabled for use with the ROPEX visualisation software ( section 8.17 "USB
interface for visualisation software ROPEXvisual®" on page 35) (standard setting: AUTOCOMP off).
The following settings are possible:
1. “OFF” (factory setting)
AUTOCOMP function switched off.
2. “ON”
The AUTOCOMP function is carried out when the AUTOCAL function ( section 8.4 "Autom. zeroing
(AUTOCAL)" on page 23) has been called up quickly twice in sequence. The pause between the end of the
first and start of the second execution of AUTOCAL must be less than 2.0 seconds. The second execution of
AUTOCAL lasts only about 2.0 seconds and contains the AUTOCOMP function.
If the pause between the two executions is longer than 2.0 seconds, the normal AUTOCAL function is carried
out the second time.

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Device functions

AUTOCAL- <2.0 s
Signal
24 VDC

0
t

Function
AUTOCOMP

AUTOCAL
0
t
“AUTOCAL”
LED
Lights up

Off
t

“OUTPUT”
LED
Lights up

Off
t

During execution of the AUTOCOMP function, the “OUTPUT” LED flashes several times and the actual value
output (terminal 17+13) goes to 0…3 °C (i.e. approx. 0 VDC).
3. “AUTO”
With this setting, the AUTOCOMP function is automatically started after a successful execution of the
AUTOCAL function.

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 Device functions

AUTOCAL-
Signal
24 VDC “AC”

0
t

Function
AUTOCOMP

AUTOCAL
0
t
“AUTOCAL”
LED
Lights up

Off
t

“OUTPUT”
LED
Lights up

Off
t

During execution of the AUTOCOMP function, the “OUTPUT” LED flashes several times and the actual value
output (terminal 17+13) goes to 0…3 °C (i.e. approx. 0 VDC).

8.11 Temperature diagnosis

An additional temperature diagnosis can be activated with the ROPEX visualisation software ( section 8.17
"USB interface for visualisation software ROPEXvisual®" on page 35). Here, the RES-5027 checks whether the
ACTUAL temperature lies within a settable “good window” tolerance band around the SETPOINT temperature.
The lower (  low ) and upper (  high ) tolerance band limit are set at the factory to -10 K and +10 K, respectively.
These values can be set separately from each other with the ROPEX visualisation software.
After activation of the START signal, if the ACTUAL temperature lies within the specified tolerance band, the tem-
perature diagnosis is switched on. If the ACTUAL temperature leaves the tolerance band, the related error no.
307, 308 is output and the alarm output switches on ( section 8.22 "Error messages" on page 37).

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Device functions

ACTUAL temperature
Set+  high

Setpoint

Set+  low

Time
Alarm
307

If the temperature diagnosis has not switched on before the START signal is deactivated (i.e. The ACTUAL tem-
perature has not exceeded the lower tolerance band limit or dropped below the upper tolerance band limit), the
related error no. 309, 310 is output and the alarm relay switches on.
A delay time (0...9.9 s.) can also be set with the ROPEX visualisation software. After the lower tolerance band limit
is exceeded, the temperature diagnosis takes place only after the parameterised delay time has expired. As a
result, the temperature diagnosis can be intentionally suppressed, such as during a temperature drop caused by
closing the welding jaws.
The values for the lower and upper tolerance band limit that can be set in the ROPEX visualisation software are
identical to the values for the “Temperature OK” signal ( section 8.12 "“Temperature reached” or “Temperature
OK” signal" on page 31).

8.12 “Temperature reached” or “Temperature OK” signal

In addition to the temperature diagnosis, the RES-5027 provides a digital switch output for the “Temperature
reached” or “Temperature OK” signal at its connection terminal 19. This signal switches through a semiconductor
output according to +24 VDC when the currently measured temperature is in the defined monitoring band
( section 8.11 "Temperature diagnosis" on page 30) or the measured temperature has reached 95% of the set-
point value.

RES-5027
+24 VDC
12

TEMP. OK
19

GND

While the constant power setting mode is active ( section 8.7 "CH-1 signal" on page 26) this
! output remains inactive.

The switching behaviour can be set through the ROPEX visualisation software. The following operating modes
can be selected:

Version 3 RES-5027 Page 31

 Device functions

1. OFF
2. Active when temp. reached
3. Active when ACTUAL=SETPOINT
4. Active when ACTUAL=SETPOINT

8.12.1 Operating mode “OFF”

The output signal always remains switched off.

8.12.2 “Temp. Reached” operating mode

If the ACTUAL temperature of the heating element reaches more than 95% of the SETPOINT welding tempera-
ture, the output signal is switched on. This can be used for process monitoring, for example, or for control of the
closing process of the welding tools.
The output signal is switched off with the deactivation of the START signal or when an alarm occurs.

Actual value
Setpoint
95% of setpoint

Time
Input
START
24 VDC
0V
Time
Output
„Temp. OK“
Conducting
Not conducting
Time

8.12.3 “ACTUAL=SETPOINT” operating mode

After activation of the START signal, if the actual temperature lies within the specified tolerance band, the output
signal is switched on (see following graphic):

Page 32 RES-5027 Version 3

Device functions

Actual value
Setpoint+ high

Setpoint

Setpoint+ low

Time
Output
“Temp. OK”
Conducting
Not conducting
Time

As soon as the ACTUAL temperature is again within the specified tolerance band, the output signal is switched
back on again.

8.12.4 “ACTUAL=SETPOINT wL” operating mode

After activation of the START signal, if the actual temperature lies within the specified tolerance band, the output
signal is switched on (see following graphic):

Actual value
Setpoint+  high

Setpoint

Setpoint+  low

Time
Output
“Temp. OK”
Conducting
Not conducting
Time

If the actual temperature leaves the tolerance band, the output signal is switched off.
The output signal remains switched off when the actual temperature later lies within the tolerance band.
At the end of the welding procedure, it can be checked whether the output signal is still switched on and so whether
the actual temperature was within the defined tolerance band during the entire welding procedure.
The output signal is not switched off until the next activation of the START signal or when an alarm occurs.

8.13 Heat-up time monitoring

An additional heat-up time monitoring can be activated with the ROPEX visualisation software ( section 8.17
"USB interface for visualisation software ROPEXvisual®" on page 35).
This monitoring is activated when the START signal is switched on. The RES-5027 then monitors the time until
the ACTUAL temperature has reached 95% of the setpoint temperature. If this takes longer than the parameter-
ised time, error no. 304 is output and the alarm output switches on ( section 8.22 "Error messages" on page 37).

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 Device functions

ACTUAL temperature

Setpoint
95% of setpoint

Moni-
toring

Time
Heat-up time Alarm
304

8.14 Restart delay after Reset

This parameter is first available as from firmware version 302.

!
After acknowledging an alarm with the RESET signal, the RESISTRON® temperature controller RES-5027 waits
until any contactor Kb connected has closed the heating circuit again. Only after this waiting time has elapsed
measuring pulses are generated in order to determine the current ACTUAL temperature and to carry out error
diagnostics.

This parameter can be used only with the Visualization software ( section 8.17 "USB interface for
! visualisation software ROPEXvisual®" on page 35).

This restart delay is 0.2 s by default and can be adjusted with the parameter „Restart delay after Reset“. This
allows slower switching contactors to be used.

8.15 Maximum measurement pause

This parameter is first available as from firmware version 302.

!
If the RESISTRON® temperature controller RES-5027 determines in control mode (START signal active), that the
current ACTUAL temperature is greater than the setpoint, the power supply to the heatsealing band is reduced. If
the power reduction is not sufficient, the low-power measuring pulses, which determine the current ACTUAL tem-
perature, are paused. This measurement pause can last up to 10 periods in the default setting. During this meas-
urement pause, the controller cannot react to a change in the ACTUAL temperature.
In certain applications it may be useful to shorten this maximum measurement pause, e.g. if the higher ACTUAL
temperature values are caused by measurement errors. For these cases the maximum measuring pause can be
shortened with the parameter „Maximum measurement pause“.

This parameter can be used only with the Visualization software ( section 8.17 "USB interface for
! visualisation software ROPEXvisual®" on page 35).

Page 34 RES-5027 Version 3

Device functions

A measuring pause that is set too small can lead to an increased temperature if the system is incor-
! rectly dimensioned (secondary voltage of the impulse transformer is too large) or if the sealing tem-
peratures are low.

8.16 Booster connection

The controller RES-5027 has a connection for an external switching amplifier (booster) as standard. This connec-
tion (at the terminals 21+22) is required at high primary currents (constant current > 5 A, impulse current > 25 A).
The switching amplifier must be connected in accordance with section 6.8 "Connection diagram with booster con-
nection" on page 15.

The connection line to the external switching amplifier must not exceed a length of 1 m and must be
! twisted to avoid EMC interference.

8.17 USB interface for visualisation software ROPEXvisual®

A USB interface (type micro-USB) is available for system diagnosis and process visualisation. A data connection
can be built up with the ROPEX visualisation software ROPEXvisual® over this USB interface.

12 13 14 15 16 17 18

Vis u al

5 6 7 8 9 10 11

PROCESS CONTROL
EQUIPMENT
E464680
www.ROPEX .de
1 2 3 4 Made in Germany

There is a separate documentation available for the ROPEX visualisation software. The software and the docu-
mentation are available in the download area (search term: “Visual”).

8.18 AUX interface

Internal interface for diagnosis and maintenance. The interface is currently not available.

ALARM OUTPUT DE-ENERGIZED

CONFIGURATION (AT ALARM)
ENERGIZED
AUX

0
78 9
1
2 34
6

Version 3 RES-5027 Page 35

 Device functions

8.19 Data storage for error messages and AUTOCAL

To make error diagnosis easier in ongoing operation, the controller RES-5027 has data storage for error messages
and executed AUTOCAL processes.
The last 400 messages are stored. These can be read and displayed with the ROPEX visualisation software.
The RES-5027 also has an integrated clock ( section 8.20 "Integrated clock (date and time)" on page 36). The
messages are then stored with the date and time specified (time stamp).

The stored messages can be exported as a csv-file. If needed, ROPEX can evaluate the exported file
! and create an error diagnosis.

8.20 Integrated clock (date and time)

The RES-5027 has an integrated clock. The messages in data storage are stored with the date and time specified
(time stamp). This permits a more precise attribution of error messages.
The integrated clock can only be set and read out using ROPEX visualisation software.
A maintenance-free condenser is used for operation of the clock. There is no installed battery that has to be
changed.
The controller must be switched on for at least 3 hours to charge the clock condenser completely. When the con-
denser is switched off, a fully charged condenser can operate the clock for approx. 2…4 weeks. If the controller
is switched off longer, the date and time must be set again. This must be done with the ROPEX visualisation soft-
ware ( section 8.17 "USB interface for visualisation software ROPEXvisual®" on page 35).
The condenser is discharged when shipped from the factory. During initial start-up of the controller, the clock must
be set when the error messages in the data storage are to be stored with date and time.
Operation of the controller is possible without the clock being set. Then only invalid values for the date and time
are stored in the data storage. The behaviour of the temperature controller is not influenced by this.

8.21 System monitoring/alarm output

To increase operational safety and avoid incorrect welding, this controller has hardware and software measures
for error diagnosis and output of differentiated error messages. Both the outer wiring and the internal system are
monitored thereby.
This characteristic helps the operator considerably in localising a defective operating status.
A system malfunction is reported or differentiated through the following elements:

A.) Red LED “ALARM” at the controller with three statuses:

1. Flashes quickly (4 Hz):
Means that the AUTOCAL function should be performed (error no. 104…106, 211, 302, 303).
2. Flashes slowly (1 Hz):
Means that the system configuration is incorrect and therefore the executed zeroing (AUTOCAL function) was
not successful ( section 7.2 "Device configuration" on page 16). This corresponds to the error numbers
111…114.
3. Lights up continuously:
Displays that malfunctions are present that prevent a start-up (error no. 101…103, 107, 108, 201…203, 307,
308, 9xx).
In cases 1 and 2, when the START signal is also activated.
These are usually external wiring errors.

Page 36 RES-5027 Version 3

Device functions

B.) Alarm output signal at the controller (terminal 18):

This is logic output in the factory setting:
• LOW (OPEN) in the operating statuses A.1) and A.2), but becomes HIGH (closed) when a START signal is
issued in this status.
• HIGH (CLOSED) in case A.3)

If the alarm output is configured differently than in the factory setting( section 7.2.3 "Configura-
! tion of the alarm output" on page 17), these statuses are inverted.

C.) Output of the error number via actual value output 0…10 VDC (terminal 17+13):
As a temperature display is not required in case of malfunction, the actual value output is used to output the error
in case of alarm.
Offered for this purpose, within the 0…10 VDC range, are 13 voltage levels, each of which has one error number
assigned. ( section 8.22 "Error messages" on page 37).
For statuses that require AUTOCAL – or when the device configuration is not correct – (error no. 104…106,
111…114, 211, 302, 303), the actual value output switches back and forth between the voltage value that corre-
sponds to the error and the end value (10 VDC, i.e 300 °C or 500 °C) with 1 Hz. If the START signal is output
during these statuses, the voltage value no longer changes.
Through the analogue input of a PLC – and a corresponding evaluation – a selective error detection and error dis-
play can be implemented simply and at low cost ( section 8.22 "Error messages" on page 37).
An error message can be reset by applying the RESET signal or switching the controller off and on.
Resetting the error message using the RESET signal becomes effective only when the RESET signal is switched
off.
Invalid error messages can occur when the controller is switched off due to the undefined operating status. This
must be considered in evaluating the higher-level controller (e.g. PLC) to avoid false alarms.

8.22 Error messages

The following table shows the assignment of the output analogue voltage values at the actual value output to the
errors that occur. In addition, the cause of the errors and the necessary measures to remedy them are described.
The simplified circuit diagram in section 8.23 "Error ranges and causes" on page 41 permits fast and efficient error
remedy.
The controller outputs at the actual value output 13 voltage levels for error diagnosis. Internally in the controller,
the error messages are differentiated in even more detail. The described error numbers can be displayed with the
ROPEX visualisation software ( section 8.17 "USB interface for visualisation software ROPEXvisual®" on
page 35). The error search can thus be performed even more effectively.

Evaluation of the actual value output for detection of an error message - e.g. in the higher-order
!controller - must be done with an adapted tolerance window to avoid incorrect evaluations. The tol-
erances of the actual value output must be observed ( section 10 "Technical data" on page 44).

Version 3 RES-5027 Page 37

 Device functions

Part 1 of 3: Error messages (malfunctions)

NOTE: The specified error messages are output as malfunctions (actual value output emits constant error
voltage; alarm LED is continuously lit; alarm relay is active).

Actual
value Measure of machine in
Error Measure if initial start-
output Cause operation, heating ele-
no. up
Voltage ment not changed
[V]

101 0.66 Current signal missing Error range  Error range 

102 1.33 Voltage signal missing Error range  Error range 

Voltage and current signals

103 2.00 Error range  Error ranges 
missing

107 Temperature jump downward Error ranges  Error ranges 
108 Temperature jump upward (“Loose connection”) (“Loose connection”)

307
2.66
308 Temperature too low/high
- -
309 ( chap. 8.11)

310

Network frequency missing/

201
fluctuates

Network frequency too large/

202 3.33 Check network Check network
fluctuates

Network frequency too small/

203
fluctuates

Heat-up time too long

304 4.00 Perform RESET Perform RESET
( chap. 8.13)

Network voltage/synchronising
901 Replace device Replace device
signal missing

913 Triac defective Replace device Replace device

914
4.66
915 Int. error, device defective Replace device Replace device

916

917 Slide switch for alarm output

Check slide switch Check slide switch
918 incorrect

Page 38 RES-5027 Version 3

Device functions

Part 2 of 3: Error messages (warnings)

NOTE: The specified error messages are first output as warnings (actual value output switches between two
values; alarm LED flashes; alarm output is not active). After activation of the START signal, it is output as a
malfunction (actual value output no longer changes, see bold-italic values; alarm LED is permanently lit; alarm
output is active).

Actual
value Measure of machine in
Error Measure if initial start-
output Cause operation, heating ele-
no. up
Voltage ment not changed
[V]

Current signal incorrect

104 Impulse transformer incorrectly
sized

Voltage signal incorrect Perform AUTOCAL,

105 Impulse transformer incorrectly Check transformer speci-
sized fication,
Error ranges 
Voltage and current signal
incorrect
106
Impulse transformer incorrectly
5.33 sized Error ranges 
 10  (“Loose connection”)
Temperature too low
Calibration not performed
302 Loose connection
Ambient temperature fluctu- Perform AUTOCAL
ates and/or
Temperature too high Error ranges 
Calibration not performed (“Loose connection”)
303 Loose connection
Ambient temperature fluctu-
ates

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

Version 3 RES-5027 Page 39

 Device functions

Part 3 of 3: Error messages (warnings)

NOTE: The specified error messages are first output as warnings (actual value output switches between two
values; alarm LED flashes; alarm output is not active). After activation of the START signal, it is output as a
malfunction (actual value output no longer changes, see bold-italic values; alarm LED is permanently lit; alarm
output is active).

Actual
value Measure of machine in
Error Measure if initial start-
output Cause operation, heating ele-
no. up
Voltage ment not changed
[V]

6.66 Current signal incorrect, Error range , Error ranges 

111
 10  Calibration not possible Check configuration (“Loose connection”)

7.33 Voltage signal incorrect, Error range , Error ranges 

112
 10  Calibration not possible Check configuration (“Loose connection”)

Voltage/current signal incor-

8.00 Error ranges , Error ranges 
113 rect,
 10  Check configuration (“Loose connection”)
Calibration not possible

Perform AUTOCAL Perform AUTOCAL

Temperature fluctuates, and/or and/or
114
Calibration not possible Error ranges  Error ranges 
(“Loose connection”) (“Loose connection”)
8.66 Ext. calibration temperature too Perform AUTOCAL with Perform AUTOCAL with
115  10  large, ext. calibration tempera- ext. calibration tempera-
Calibration not possible ture ≤40 °C ture ≤40 °C

Ext. calibration temperature Perform AUTOCAL with Perform AUTOCAL with

116 fluctuates, stable ext. calibration stable ext. calibration
Calibration not possible temperature temperature

Page 40 RES-5027 Version 3

Device functions

8.23 Error ranges and causes

5 1 2 2 9

6 3
Temperature
4 controller

HARDWARE
9

8
UR
7
1
IR
8

Explanations of the possible error causes can be taken from the following table.

Malfunc-
Explanations Possible causes
tion range

Interruption of the load circuit after - Wire break, heating element break
the UR pickup point - Contacting at the heating element defective

Interruption of the signal from the - IR measurement line from the transformer interrupted
transformer

- Line break, Triac defective in the controller

Interruption of the primary circuit
- Primary coil of the impulse transformer interrupted

Interruption of the secondary cir- - Wire break
cuit in front of the UR pickup point - Primary coil of the impulse transformer interrupted

 UR signal missing - Measurement line interrupted

- Heating element is partially bridged through a conducting

 Partial short circuit (Delta R)
part (hold-down device, safety rail, etc.)

- Wire break, heating element break

 Interruption of the parallel circuit
- Contacting at the heating element defective

- Heating element incorrectly installed, insulation at the head

 Complete short circuit of the rail missing or incorrectly installed
- Conducting part bridges heating element completely

 UR signal incorrect - U2 outside of the permitted range of 0.4…120 VAC

IR signal incorrect - I2 outside of the permitted range of 30…500 A

 Coils through transformer incor- - Check number of coils (For current < 30 A, two or more
rect coils are required)

Version 3 RES-5027 Page 41

 Factory settings

Malfunc-
Explanations Possible causes
tion range

- Hardware error (replace controller)

- Slide switch for alarm relay defective or not in correct posi-
 Internal device error
tion
- Network voltage missing

9 Factory settings
The RESISTRON® temperature controller RES-5027 is configured as follows from the factory:

Rotary encoder switch Heating element alloy: Alloy A20

for Temperature range: 300 °C
Heating element alloy Maximum temperature: 300 °C
and SWITCH POS.
0
1
Temperature range 0 4
5
Rotary encoder switch: Position “0”
12
789

(June 2003 and later) 8 300°C

34
6

9
5

Slide switch Alarm output active in case of alarm

for ALARM OUTPUT DE-ENERGIZED
CONFIGURATION (AT ALARM)
Alarm output ENERGIZED
AUX

0
1
789

2 34
6

Automatic AUTOCOMP: OFF

Phase correction
(AUTOCOMP)
[X]

Measurement impulse Measurement impulse duration: 1.7 ms

duration

[X]

“Temperature OK” Tolerance band: -10 K…+10 K

signal

[X]

Temperature Temperature diagnosis: OFF

diagnosis

[X]

Page 42 RES-5027 Version 3

Factory settings

Heat-up time Heat-up time monitoring: OFF

monitoring

[X]

[X] Only with ROPEX visualisation software

Version 3 RES-5027 Page 43

 Technical data

10 Technical data
Design Housing for electrical cabinet mounting
On TS35 top hat rail (35 mm) in accordance with DIN EN 50022 latchable
Basic surface: 90 x 75 mm; depth: 135 mm (incl. connection terminals)

Network voltage 110 VAC -15%…300 VAC +10%

Connected between neutral and an outside conductor
or
110 VAC -15%…480 VAC +10%
Connected between two outside conductors

The voltage between outside conductor and earth must not exceed
! 300 VAC.

Power supply net- Symmetrical TN- or TT-network

work Overvoltage category III

Operation in voltage-free network (eg IT network) only after checking

! with ROPEX.

Network frequency 47…63 Hz, automatic frequency adjustment in this range

Current consumption Imax = 5 A (ED = 100%)

(Primary current of the Imax = 25 A (ED = 20%, duration of play 1 min)
impulse transformer)

24 VDC supply 24 VDC, Imax = 200 mA (control mode), 1 A (switch-on current),

Terminals 12+13 protected against faulty polarisation
Tolerance: ±10%
SELV or PELV supplied from maximum 300 VAC, Cat II

Measurement range Secondary voltage UR: 0.4…120 VAC

Secondary current IR: 30…500 A (transformer PEX-W4/-W5)
 ROPEX application report

Heating element type Besides setting through the rotary encoder switch (see below), the setting for the
and temperature temperature range and temperature coefficient can be performed through the
range ROPEX visualisation software ( section 8.17 "USB interface for visualisation
software ROPEXvisual®" on page 35):
Temperature range: 200 °C, 300 °C, 400 °C or 500 °C
Temperature coefficient: 400…4000 ppm/K (variable setting range)

Five areas can be set on the device through rotary encoder switches:
Temperature coefficient 1100 ppm/K, 0…300 °C (e.g. alloy A20)
Temperature coefficient 780 ppm/K, 0…300 °C (e.g. alloy L)
Temperature coefficient 1100 ppm/K, 0…500 °C (e.g. alloy A20)
Temperature coefficient 780 ppm/K, 0…500 °C (e.g. alloy L)
Temperature coefficient 3500 ppm/K, 0…300 °C (e.g. LEX3500)
Standard value 300 °C, alloy A20

Analogue input 0…10 VDC, Imax = 5 mA, electrically separated from the heating circuit
(Setpoint) corresponding to 0…300 °C or 0…500 °C
Terminal 16+13 or through an external precision potentiometer PD-3 or PD-5 (R = 2 kOhm)
0…2 kOhm corresponding to 0…300 °C or 0…500 °C

Page 44 RES-5027 Version 3

Technical data

Analogue output 0…10 VDC, Imax = 5 mA, electrically separated from the heating circuit
(Actual value) corresponding to 0…300 °C or 0…500 °C
Terminal 17+13 Precision: ±1% plus 50 mV

Reference voltage +10 VDC / ±5%, Imax = 5 mA

output

Digital logic level LOW (0 V): 0…2 VDC

Terminals 5, 6, 7, HIGH (24 VDC): 8…30 VDC (Current consumption max. 6 mA)
galvanically separated from the heating circuit, protected against faulty polarisa-
tion

Switch output for Umax = 30 VDC

“Temperature Imax = 50 mA
reached” signal UON < 2 V (saturation voltage)
or galvanically separated from the heating circuit, short-circuit-proof.
“Temperature OK”
signal

Alarm output Umax = 30 VDC

Terminal 18 Imax = 200 mA
UON < 2 V (saturation voltage)
galvanically separated from the heating circuit, short-circuit-proof.
Can be inverted through slide switch.

Power loss Max. 20 W

Ambient conditions Maximum altitude 2000 m

Ambient temperature: +5…+45 °C
Maximum relative humidity: 80% at temperatures up to +31 °C, decreasing line-
arly to 50% relative humidity at +45 °C

Degree of protection IP 20

UL file E464680

Mounting When mounting the device, a surrounding safety dis-

tance of 20 mm (e.g. To other devices and wiring)
must be maintained.

When mounting on a horizontal top hat rail, the mov-

able latch, which is necessary for fastening, must face
downward.

When mounting on a vertical top hat rail, end holders must be installed on both
sides to fasten the controller mechanically.

Weight Approx. 0,5 kg (incl. plug-in connector parts)

Housing material Plastic, polycarbonate, UL-94-V0

Version 3 RES-5027 Page 45

 Dimensions

Connecting cable Rigid or flexible; 0.2…2.5 mm² (AWG 24…12) through pluggable terminals
Type / cross-sections
Pluggable terminals: Tightening torque: 0.5…0.6 Nm
(Screwdriver: SZS 0.6x3.5 mm)

If ferrules are used, they must be crimped in accordance with

! DIN 46228 and IEC/EN 60947-1. Otherwise, correct electrical contact
in the terminals is not guaranteed.

11 Dimensions

135,0
113,0

75,0 90,0

12 Modifications (MODs)
The RESISTRON® temperature controller RES-5027 is suitable for very many welding applications due to its uni-
versal design.
A device modification (MOD) is available for the RESISTRON® temperature controller RES-5027 to implement
special applications.
The modifications must be ordered separately.

MOD 01
Supplemental booster for small secondary voltages (UR = 0.25…16 VAC). This modification is necessary for very
short or low-resistance heating elements, for example.

Page 46 RES-5027 Version 3

How to order

13 How to order
Illustrations are examples.

Controller RES - 5027

Art. no. 7502700
Scope of delivery: Controller with plug-in connector parts (without transformer)

Modification MOD . . (optional, if necessary)

e.g.
01: MOD 01, art. no. 800001 (suppl. booster for small
voltage)

The article numbers of the controller and of the desired modification (optional) must
be specified when ordering.
e.g. RES-5027 + MOD 01 (controller with suppl. booster for small voltage)
order of art. no. 7502700 + 800001

Current transformer PEX-W5

Art. no. 885107

Monitoring current transformer MSW-2

Art. no. 885212

Line filter LF- . . . . .

06480: Continuous current 6 A, 480 VAC, art. no. 885500
(with UL certification)
10520: Continuous curr. 10 A, 520 VAC, art. no. 885504
(with UL and CSA certification)
35480: Continuous curr. 35 A, 480 VAC, art. no. 885506
50520: Continuous curr. 50 A, 520 VAC, art. no. 885509
(with UL and CSA certification)

Impulse transformer
For design and order specifications, see ROPEX applica-
tion report
Design in accordance with EN 61558
Available with UL certifications and thermal switch, if nec-
essary.
In addition, we can individually design and offer you an
upstream transformer.

Potentiometer PD- .
3: For 300 °C range, art. no. 881103
5: For 500 °C range, art. no. 881105
Scope of delivery: Potentiometer with digital button

Version 3 RES-5027 Page 47

 How to order

Temperature display ATR- .

3: 300 °C range, art. no. 882130
5: 500 °C range, art. no. 882150

Booster B- . . .
075415: Impulse loaded 75 A, 415 VAC, art. no. 885302
100400: Impulse loaded 100 A, 400 VAC, art. no. 885304

Lines
For design and order specifications, see ROPEX applica-
tion report

Additional accessories  “Accessories” brochure

Page 48 RES-5027 Version 3

Index

14 Index
Numbers F
24VDC supply 44 Factory settings 42
Functional principle 7
A Fuse 11
Actual value output 22
Alarm output 36, 45 H
Alarm relay 17 HEAT 19, 24
Alloy 17, 19 Heating element type 44
Ambient conditions 45 Heat-up time monitoring 33
Ambient temperature High altitude 45
45 How to order 47
Analogue input 45 Humidity 45
Analogue output 45
Application Report 8, 12 I
AUTOCAL 8, 19, 23 Impulse transformer 11, 47
AUTOCAL function is blocked 24 Installation 8
AUTOCOMP 28 Installation rules 8
Automatic phase correction 28
Automatic zeroing 8, 19, 23
AUTOTUNE 8 L
AUX interface 35 Line filter 4, 11, 12
Auxiliary voltage 14
M
B Maintenance 5
Blocking of the “AUTOCAL” function Maximum measurement pause 34
24 Measurement impulse duration 28
Booster 48 Measurement pause 34
Burning in the heating element 17, 19 Measurement range 44
MOD 46, 47
Modification 46, 47
C Monitoring current transformer 47
Changing the heating element 18, 19 Mounting 8, 45
Circuit-breaker 11 MSW-2 47
Clock 36
Commissioning 16, 18
Connection diagram 14 N
Current transformer 12, 47 Network frequency 8, 44
Network voltage 44
D
Data storage 36 O
Date 36 Operating elements 20
Degree of protection 45 Over-current protection 11
Design 44
Device configuration 16 P
Device view 16 PEX-W4/-W5 4, 12
Dimensions 46 PEX-W5 47
Disposal 5 Phase correction 28
Potentiometer 22, 47
E Power loss 45
Error diagnosis 8 Power supply 11
Error messages 37 Power supply network 44
Error ranges 41
R
Reference voltage output 45

Version 3 RES-5027 Page 49

 Index

RESET signal 25 “Temperature reached” signal 31, 45

Restart delay 34 Temperature regulation 7
ROPEXvisual 35 Temperature setting 21
Thermal impulse process 7
S Time 36
Setpoint potentiometer 22 Time stamp 36
Setpoint specification 21, 44 Transformer 4, 11, 47
Setup stipulations 9 Transportation 5
START signal 19, 24
System diagnosis 35 U
System monitoring 36 UL file 45
USB interface 35
T Use 7
TCR 4, 17
Technical data 44 V
Temperature coefficient 4, 17 Visualisation software 35
Temperature diagnosis 30, 33
Temperature display 22, 23, 48 W
“Temperature OK” signal 31 Wiring 9, 11
Temperature range 17, 44

Page 50 RES-5027 Version 3