RESISTRON

RES-5010

Operating
instructions

Important features

• Complete control via PROFINET interface („Conformance Class C“, IO/RT and IRT acc. to IEC
61784-2), (2 x RJ-45)
• 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
• Analogue output 0…10 VDC for ACTUAL temperature
• Alarm function with error diagnosis
• Heating element alloy and temperature range can be selected

• Wide voltage range for the use of 110…480 V1 (as from 02/2021)
• Eight channels for administration of various calibration values

• Micro-USB interface for ROPEXvisual®

• cULus approval
Version 4
03.03.21

1. Standard: 415 V, optional and on request: 480 V

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 . . . . . . . . . . . . . . . . . . . . 22
2 General information .................. 3 8.1 LEDs and controls . . . . . . . . . . . . . . . 22
2.1 Copyright . . . . . . . . . . . . . . . . . . . . . . . 4 8.2 PROFINET communication . . . . . . . . 24
2.2 Intended use . . . . . . . . . . . . . . . . . . . . 4 8.3 Device master file (GSDML) . . . . . . . 24
2.3 Heatsealing band ................ 4 8.4 Communication protocol . . . . . . . . . . 25
2.4 Impulse transformer .............. 4 8.5 Input data . . . . . . . . . . . . . . . . . . . . . . 26
2.5 Current transformer PEX-W4/-W5 . . . . 5 8.6 Output data . . . . . . . . . . . . . . . . . . . . 28
2.6 Line filter . . . . . . . . . . . . . . . . . . . . . . . 5 8.7 Parameter data . . . . . . . . . . . . . . . . . 31
2.7 Maintenance . . . . . . . . . . . . . . . . . . . . 5 8.8 Integrated web server . . . . . . . . . . . . 41
2.8 Transportation . . . . . . . . . . . . . . . . . . . 5 8.9 Undervoltage detection . . . . . . . . . . . 45
2.9 Disposal . . . . . . . . . . . . . . . . . . . . . . . . 5 8.10 Temperature meter (actual value
output) . . . . . . . . . . . . . . . . . . . . . . . . 46
2.10 DECLARATION OF CONFORMITY . . 7
8.11 Booster connection . . . . . . . . . . . . . . 47
3 Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8.12 USB interface for visualization software
4 Functional principle .................. 8 ROPEXvisual® . . . . . . . . . . . . . . . . . . 47
5 Device features . . . . . . . . . . . . . . . . . . . . . . 8 8.13 AUX interface . . . . . . . . . . . . . . . . . . 48

6 Mounting and installation . . . . . . . . . . . . . . 9 8.14 Total cycle counter . . . . . . . . . . . . . . 48

8.15 Operating hours counter . . . . . . . . . . 48
6.1 Installation sequence . . . . . . . . . . . . . . 9
6.2 Installation steps . . . . . . . . . . . . . . . . 11 8.16 Data memory for error messages and
AUTOCAL . . . . . . . . . . . . . . . . . . . . . 48
6.3 Power supply . . . . . . . . . . . . . . . . . . . 12
8.17 Built-in clock (date and time) . . . . . . . 48
6.4 Line filter . . . . . . . . . . . . . . . . . . . . . . 13
8.18 System monitoring / alarm output . . . 49
6.5 Current transformer PEX-W4/-W5 . . . 13
8.19 Error messages . . . . . . . . . . . . . . . . . 50
6.6 Wiring diagram (standard) . . . . . . . . . 15
8.20 Fault areas and causes . . . . . . . . . . . 54
6.7 Wiring diagram with booster
connection . . . . . . . . . . . . . . . . . . . . . 16 9 Factory settings . . . . . . . . . . . . . . . . . . . . . 56

7 Startup and operation . . . . . . . . . . . . . . . . 17 10 Technical data . . . . . . . . . . . . . . . . . . . . . . 56

7.1 View of the device . . . . . . . . . . . . . . . 17 11 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Device configuration . . . . . . . . . . . . . 17 12 Modifications . . . . . . . . . . . . . . . . . . . . . . . 59
7.3 Replacing and burning in the heatsealing 12.1 Modifications (MODs) . . . . . . . . . . . . 59
band . . . . . . . . . . . . . . . . . . . . . . . . . 19
13 How to order . . . . . . . . . . . . . . . . . . . . . . . . 60
7.4 Startup procedure . . . . . . . . . . . . . . . 20
14 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Page 2 RES-5010 Version 4

Revision list

1 Revision list

Version Change

1 • Creation of documentation

2 • Change to one column layout

• ROPEX logo changed
• Covering page with important features
• Additions in general information
 section 2 "General information" on page 3
• Addition in Communication protocol: Status bit measurement interruption
 section 8.6.10 "Measurement interruption (MU)" on page 30
• Extension of slot 1, subslots 4 with index 16 to 48: absolute calibration resistances
 page 33
• Terminal number of analog output corrected
 section 8.7.10 "Automatic phase angle compensation (AUTOCOMP)" on page 37
• Extension of integrated webserver: presentation of calibration values
 section 8.8.6 "Calibration page" on page 44
• Updating of how to order
 section 13 "How to order" on page 60

4 • Extension communication protocol: command bit constant regulation ratio

 section 8.5.6 "Constant regulation ratio (KS)" on page 28
• Extension parameter data: Startup delay after Reset (index 46/47) and maximum measurement
pause (index 48)
 section 8.7 "Parameter data" on page 31
• New: section 8.7.14 "Restart delay after Reset" on page 41
• New: section 8.7.15 "Maximum measurement pause" on page 41
• Extension parameter data: TCR Calculator in slot 1, subslot 5
 section 8.7 "Parameter data" on page 31
• New: section 8.7.2 "TCR Calculator" on page 35
• Correction of the parameter structure of the calibration data in slot 1, subslot 4
 section 8.7 "Parameter data" on page 31

• New: Voltage supply range changed to max. 480 VAC1 (as from 02/2021)
 section 10 "Technical data" on page 56
1. Standard: 415 VAC, optional and on request: 480 VAC

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.

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 General information

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.
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 pro-
vided 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.

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General information

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 con-
troller (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 doc-
ument.

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 7. This device must be installed and connected
according to the instructions contained in section "Power supply" as well as the separate documentation enclosed
with the line filter.

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.

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 General information

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, trans-
formers, 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)

Version 4 RES-5010 Page 7

 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 RESISTRON®
temperature controller. 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 Device features
The RESISTRON® temperature controller RES-5010 is equipped with a PROFINET interface. Through this inter-
face, all functions and parameters can be parameterised by means of the higher level machine controller. In addi-
tion, important controller information is queried and can be processed accordingly.

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Mounting and installation

The ACTUAL temperature of the heating element is output through the PROFINET interface and through an ana-
logue output 0…10 VDC. The real heating element temperature can be visualised on an external display instru-
ment (e.g. ATR-x) or via the operating unit of the machine controller.
The RES-5010 has an integrated error diagnosis that checks both the external system (heating element, wiring,
etc.) and the internal electronics. A differentiated error message is output through the PROFINET interface in case
of malfunction.
To increase operational security and immunity to interference, all PROFINET signals from the controller and
heating circuit are electrically isolated.
Adjustment for different heating element alloys (alloy A20, Vacodil, etc.) and setting of the temperature range to
be used (0…300 °C or 0…500 °C) can be made through coding switches on the temperature controller itself or
through the PROFINET interface.
The compact design of the RESISTRON® temperature controller RES-5010 as well as the plug-in connecting ter-
minals 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
• Eight channels permit switching of the calibration parameters during tool change.
• High control dynamics through AUTOTUNE, automatic adjustment to the controlled system
• High flexibility: The AUTORANGE function covers a secondary voltage range of 0.4 V to 120 V and a current
range of 30 A to 500 A.
• 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 VAC1 (as from 02/2021)
• Easy and convenient system diagnosis and process visualisation through the free, downloadable software
ROPEXvisual®
• Comprehensive error diagnosis over the PROFINET interface
• Booster output available for connecting a switching amplifier
• High process security through comprehensive options for evaluating the parameter data (e.g. temperature
diagnosis or heat-up time monitoring)

6 Mounting and installation

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

Mounting, installation and startup may only be performed by authorized persons who have received
! suitable instruction and are familiar with the associated risks and warranty provisions.

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 to install the RESISTRON® temperature controller RES-5010:

1. Switch off the line voltage and the 24 VDC supply, and verify that the circuit is de-energized.
2. Mount the RESISTRON® temperature controller on a standard top hat rail (DIN TS35 rail according to
DIN EN 50022) in the electrical cabinet. If several controllers are mounted on one rail, the minimum clearance

1. Standard: 415 VAC, optional and on request: 480 VAC

Version 4 RES-5010 Page 9

 Mounting and installation

specified in section 10 "Technical data" on page 56 must be allowed between them.

3. Wire the system in accordance with the instructions in section 6.3 "Power supply" on page 12, section 6.6
"Wiring diagram (standard)" on page 15, and the ROPEX Application Report. The information provided in
section 6.2 "Installation steps" on page 11 must also be observed.
Wires used for control or measuring connections must always be laid inside the building.
4. An overcurrent protective device with a maximum rating of 10 A must be fitted when the device is installed, e.g.:
- Miniature circuit breaker to EN 60898 (B, C, D, K, or Z characteristic)
- Miniature circuit breaker to UL 489 (*) (B, C, D, K, or Z characteristic)
- Fuse gG to IEC 60269
- Class CC or Class J fuse to UL 248 (*)

The overcurrent protective devices marked (*) should be used in installations conforming to UL standards.

If one such device is not adequate for the heatsealing application, two separate overcurrent protective devices
should be provided – one for the controller and one for the application ( ROPEX Application Report).
The overcurrent protective device must be located directly adjacent to the controller.
The minimum possible specification for this device is indicated in the ROPEX Application Report based on the
calculated currents. If a larger overcurrent protective device is fitted, you must match the current carrying
capacity of the other components accordingly (e.g. cables, impulse transformer etc.).
5. A disconnecting device must be provided when the system is installed; it must be marked as belonging to the
system and fitted in a readily accessible position.
If a miniature circuit breaker is used, it can also perform the function of this device.
6. Connect the RESISTRON® temperature controller to the PROFINET controller using a suitable (standard
compliant) cable.

Check that all system connections – including the terminals for the impulse transformer windings
! – are securely attached.

7. Make sure the wiring conforms to all relevant national and international installation regulations.

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Mounting and installation

6.2 Installation steps

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® tem-
I> I> ! perature 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 12 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 12).

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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 Wiring diagram (standard)

Line filter
1
Ethernet
RES-5010 LINE
TX+ 1 2
PORT 1 (RJ45)
TX- 2

RX+ 3 15
BOOSTER
OUTPUT
RX- 6 16

4 Ethernet
Termination

module
5 3
7 4
8 U1
prim.
Shield Impulse
Ethernet transformer
PORT 2 (RJ45)
(for assignment U2
see PORT 1) sec.

Ground
Must be grounded 8 Heat-
externally to UR R sealing
prevent 6 9 band
twisted
electrostatic
charging!
V+ 5 10
24 VDC POWER IR
SUPPLY 11
V- 7
Current
transformer
12
ALARM OUTPUT
max. 30 V 13

14

_
18
ATR
°C 17
+
ANALOG OUTPUT
+0...10 VDC

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 Mounting and installation

6.7 Wiring diagram with booster connection

Line filter
1
Ethernet
RES-5010 LINE
TX+ 1 2
PORT 1 (RJ45)
TX- 2 Booster
3 1
RX+ 3 15
IN OUT
RX- 6 16
4 2
4 twisted
Ethernet Max. length 1 m
Termination

module
5 3 NC
7 4 NC
8 U1
prim.
Shield Impulse
Ethernet transformer
PORT 2 (RJ45)
(for assignment U2
see PORT 1) sec.

Ground
Must be grounded 8 Heat-
externally to UR R sealing
prevent 6 9 band
twisted
electrostatic
charging!
V+ 5 10
24 VDC POWER IR
SUPPLY 11
V- 7
Current
transformer
12
ALARM OUTPUT
max. 30 V 13

14

_
18
ATR
°C 17
+
ANALOG OUTPUT
+0...10 VDC

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Startup and operation

7 Startup and operation

7.1 View of the device

PROFINET
Coding and slide LEDs ports
switches

USB interface
Terminal plan

Nameplate

Connection terminals

7.2 Device configuration

The controller must be switched off in order to configure the coding and slide switches.
!

7.2.1 Configuration of the secondary voltage and current ranges

The secondary voltage and current ranges are automatically configured during the automatic calibration function
(AUTOCAL). The voltage is configured in the range from 0.4 VAC to 120 VAC and the current in the range from
30 A to 500 A. If the voltage and / or current are outside of the permissible range, a detailed error message
appears on the controller ( section 8.19 "Error messages" on page 50).
If the secondary current I2 is less than 30 A, the secondary high-current wire must be laid twice (or several times)
through the PEX-W4, or PEX-W5 current transformer ( ROPEX Application Report).

2x

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 Startup and operation

7.2.2 Configuration of the rotary coding switch for the 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

The setting of the rotary coding switch for the temperature range and alloy can be overwritten with
! the parameter data ( section 8.7 "Parameter data" on page 31).

If the switch is set to "9", more temperature ranges and alloys can be selected in the ROPEX visualization software
( section 8.12 "USB interface for visualization software ROPEXvisual®" on page 47).

7.2.3 Configuration of the rotary coding switches for device names

These coding switches can be used to set the names of the RES-5010 devices in the PROFINET network. A new
setting does not take effect until the next time the controller is switched on.
The preset device name "RES-5010" is configured as follows, depending on the settings of the rotary coding
switches:

Rotary coding switch Device name

00 Last name assigned is static

01…FE RES-5010-01…RES-5010-FE

FF Last device name assigned and I&M data erased

Station name selectable.

Device name selectable 7 89

78 9 00
AB E
23 6

by PROFINET config tool 0...F

45

00 = Factory settings
CD
AB E
23 6
45

F0 1
Device name preset to
CD

F01 01...FE “Controller_type -XX”

7 89
FF Erase name
AB E
23 6

0...F
45

CD

78 9 (Controller_type: RES-5010 / UPT-6010)

F0 1
AB E
23 6
45

CD

F01

By assigning device names using rotary coding switches, you can replace a device in an existing machine without
a programming tool. Simply configure the replacement device with the same switch settings.
If the RES-5010 was named using a suitable PROFINET tool (e.g. Siemens STEP7), the preset device name can
be erased by means of the rotary coding switches. To do this, make sure the controller is de-energized, then set
the switches to 0xFF and switch the controller on again. It is sufficient to supply the controller with 24 VDC. No
connection is required to the PROFINET network. After the device name has been successfully erased, the red
DATA EXCHANGE LED blinks at approx. 4 Hz. The power supply to the controller must then be momentarily inter-
rupted in order for the new switch settings to take effect.

Page 18 RES-5010 Version 4

Startup and operation

In addition to the device name, restoring the factory settings by setting the rotary coding switch to
! "0xFF" also erases all I&M data in the memory.

In order to assign the device name via the PROFINET interface (e.g. using a programming tool), the
! rotary coding switch must be set to "0x00".

Note: By using a configuring tool (e.g. Siemens STEP7) to specify the PROFINET topology, you can also assign
a name automatically if the controller does not already have a device name when it is switched on. In this case,
the PLC automatically assigns it the name stored in the project.

7.2.4 Configuration of the alarm relay

Alarm relay contact

DE-ENERGIZED ALARM OUTPUT
(AT ALARM)
CONFIGURATION
opened by alarm
ENERGIZED

Alarm relay contact

AUX
closed by alarm.
(factory setting) 0
789
1
2 34
6

If the switch is set to "Alarm relay de-energized at alarm / PC CONFIGURATION", you can select more alarm
output configurations in the ROPEX visualization software ( section 8.12 "USB interface for visualization soft-
ware ROPEXvisual®" on page 47).

7.3 Replacing and burning in the heatsealing band

7.3.1 Burning in the heatsealing band

The heatsealing band is a key component in the control loop because it is not only a heating element but also a
sensor. The geometry of the heatsealing band is too complex to be discussed at length here. We shall therefore
only refer to a few of the most important physical and electrical properties.
The measuring principle used for this system requires a heatsealing band alloy with a suitable temperature coef-
ficient TCR. Too low a TCR leads to oscillation or uncontrolled heating.
If a heatsealing band with a higher TCR is used, the controller must be calibrated for it.
The first time the heatsealing band is heated to approximately 200…250 °C, the standard alloy undergoes a once-
only resistance change (burn-in effect). The cold resistance of the heatsealing band is reduced by approximately
2…3%. However, this at first glance slight resistance change results in a zero point error of 20…30 °C. The zero
point must therefore be corrected after a few heating cycles, i.e. the AUTOCAL function must be run again.
To do this, the system must be cooled off completely.
After the first heating and zeroing, the heating element is burned in and the change of resistance stabilised. The
heating element can now be used.
The burn-in effect described here does not occur if the heatsealing band has already been thermally pretreated
by the manufacturer.

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

Version 4 RES-5010 Page 19

 Startup and operation

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 Replacing the heatsealing band

The supply voltage (all poles) must be disconnected from the RESISTRON® temperature controller in order to
replace the heatsealing band.

The heatsealing band must be replaced in accordance with the instructions provided by the manu-
! facturer.

Each time the heatsealing band is replaced, you must calibrate the zero point with the AUTOCAL function while
the band (and the environment, i.e. silicone, PTFE cover, sealing bar etc.) is still cold in order to compensate pro-
duction-related resistance tolerances.
If a new heating element is used, the above-described procedure for burning in must be performed.

7.4 Startup procedure

Please also refer to section 2 "General information" on page 3 and section 3 "Use" on page 8.

Mounting, installation and startup may only be performed by authorized persons who have received
! suitable instruction and are familiar with the associated risks and warranty provisions.

7.4.1 Initial startup

Condition: The device must be correctly installed and connected ( section 6 "Mounting and installation" on
page 9).
Proceed as follows to start up the controller for the first time:
1. Switch off the line voltage and the 24 VDC supply, and verify that the circuit is de-energized.
2. Set the desired station name of the device either by means of the rotary coding switches or a suitable
PROFINET tool.
3. Link the device master file (GSDML) into the PROFINET controller ( section 8.3), then select the required
parameters, assign a name to the device, and start the communication.
4. Make sure that the higher-level controller does not send values not equal to zero to the temperature controller.
5. Switch on the line voltage and the 24 VDC supply (the order is arbitrary).
6. When the voltage is switched on, the yellow "AUTOCAL" LED lights up for approximately 0.3 seconds to indi-
cate that the controller is being powered up correctly. The red "BUS FAILURE" LED lights up as long as no
PROFINET communication is active. It does not go out again until it detects an active communication.

If the red "ALARM" LED lights up for 0.3…1.5 seconds when the voltage is switched on in addition
! to the yellow "AUTOCAL" LED, the configuration of this controller has been changed in the visual-
ization software ( section 8.12 "USB interface for visualization software ROPEXvisual®" on page 47). In
order to avoid malfunctions, please check the controller configuration before continuing the startup pro-
cedure.

7. The green "DATA EXCHANGE" LED lights up to indicate an active PROFINET communication.

Page 20 RES-5010 Version 4

Startup and operation

8. One of the following states then appears:

"ALARM" LED "OUTPUT" LED ACTION

OFF Short impulses every 1.2 s Go to step 9

BLINKS fast (4 Hz) OFF Go to step 9

LIT continuously OFF Error diagnosis ( section 8.19)

9. Activate the AUTOCAL function while the heatsealing band is still cold by setting the AC bit (AUTOCAL) in the
PROFINET protocol ( section 8.4 "Communication protocol" on page 25). The yellow "AUTOCAL" LED lights
up for the duration of the calibration process (approx. 10…15 seconds). The AA bit (AUTOCAL active) is addi-
tionally set and a voltage of approximately 0 VDC appears at the actual value output (terminals 17+18). If an
ATR-x is connected, it indicates 0…3 °C.
After the zero point has been calibrated, the "AUTOCAL" LED goes out and a voltage of 0.66 VDC (300 °C
range) or 0.4 VDC (500 °C range) appears at the actual value output. If an ATR-x is connected, it must be set
to "Z".
If the zero point was not calibrated successfully, the AL bit (alarm active) is set and the red "ALARM" LED blinks
slowly (1 Hz). In this case the controller configuration is incorrect ( section 7.2 "Device configuration" on
page 17, ROPEX Application Report). Repeat the calibration after correcting the controller configuration.
10.After the zero point has been successfully calibrated, specify a defined temperature by means of the
PROFINET protocol (set point) and set the ST bit. The RA bit (control active) is then activated and the "HEAT"
LED lights up. The heating and control process can be observed at the actual value output.
The controller is functioning correctly if the temperature (which corresponds to the signal change at the analog
output or the actual value in the PROFINET protocol) is a regular curve, in other words it must not jump
abruptly, fluctuate, or temporarily deviate in the wrong direction. This kind of behavior would indicate that the
UR measurement cable was laid incorrectly.
If an error code is displayed, proceed as described in section 8.19 "Error messages" on page 50.
11. Burn in the heatsealing band ( section 7.3 "Replacing and burning in the heatsealing band" on page 19) and
run the AUTOCAL function again.

7.4.2 Restart after replacing the heatsealing band

To replace the heatsealing band, proceed as described in section 7.3 "Replacing and burning in the heatsealing
band" on page 19.

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

Continue with section 7.4, steps 4 to 11.

Version 4 RES-5010 Page 21

 Device functions

8 Device functions
See also section 6.6 "Wiring diagram (standard)" on page 15.

8.1 LEDs and controls

RX/TX Lit or blinking if Ethernet

(yellow LED) frames are transmitted.

LINK Lit if connection exists to

(green LED) Ethernet.

AC 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)
12 13 14 15 16 17 18

Vi s u a l
BUS FAILURE Lit or blinking if no connection
(red/green exists to PROFINET.
LED)
DATA EXCH Lit (green) while data exchange
(red/green with PROFINET controller.
LED) 5 6 7 8 9 10 11

µC POWER Lit if internal power supply for !

(green LED) PROFINET interface is OK.
PROCESS CONTROL
EQUIPMENT
24V POWER Lit if external 24VDC power E464680
www.ROPEX.de
(green LED) supply is present. 1 2 3 4

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

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

AUTOCAL requested but

RS bit set (reset) function blocked (e.g. AUTOCAL executing
AC (AUTOCAL) START active)
(yellow)
LED blinks at a different frequency:
Supply voltages incorrect (too low)

Page 22 RES-5010 Version 4

Device functions

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

START requested but func-

HEAT tion blocked (e.g.
— START executing
(yellow) AUTOCAL active, set tem-
perature < 40 °C)

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

ALARM Configuration error, no Controller calibrated incor-

Error,  section 8.19
(red) AUTOCAL possible rectly, run AUTOCAL

Green: Communication
Rotary coding switches for with PROFINET controller
DATA EXCHANGE
— device name set to 0xFF is active
(red / green)
(factory setting restored) Red: Internal error in
PROFINET module

Blinks red for 3 s at 2 Hz:

Red: No communication or
BUS FAILURE No data exchange
slow / no physical connec-
(red / green) Blinks (green or yellow) at 2 Hz:
tion
DCP signal service activated via bus

LINK PORT 1, 2 Connection exists to

— —
(green) Ethernet

RX / TX PORT 1, 2
Device is transmitting / receiving Ethernet frames
(yellow)

Version 4 RES-5010 Page 23

 Device functions

8.2 PROFINET communication

The following sections only describe controller-specific functions. For general information on the PROFINET inter-
face and the system configuration, please refer to the description of your PLC.
The PROFINET interface of the RES-5010 supports "Conformance Class C" with IO/RT and IRT according to IEC
61784-2.
The controller can communicate via the PROFINET interface provided the 24 VDC supply voltage (terminals 5+7)
is present.
If no line voltage is present however (e.g. if it is switched off in order to open a door), error code 901 or 201 (error
group 7, no line voltage / sync signal) appears on the controller and the alarm relay is switched. This happens due
to the absence of line voltage. The error message can be reset by switching on the line voltage again and setting
the RS bit ( section 8.5.3 "Reset (RS)" on page 27).
You can easily process the error code that appears if the line voltage is switched off – or suppress switching of
the alarm relay – in the PLC program.

8.3 Device master file (GSDML)

The configuring tools for the PROFINET controller interpret the content of the device master files (GSDML) and
use this information to create a parameter set for the PROFINET controller which controls user data traffic. The
GSDML-V2.4-ROPEX-0150-RES-5010-20200921.XML file of the RES-5010 contains all essential controller infor-
mation for the configuration, e.g. the I/O data description, parameter descriptions, error messages etc. The device
master files and the associated image files (.BMP) for visualization in the configuring tool can be requested by e-
mail ([email protected]) or downloaded from our website (https://ropex.de). If the controller already has an IP
address, the device master file can also be downloaded from the integrated web server.
After linking the required device master file into the configuring tool, you must assign a unique name to the con-
troller (device initialization). The controller is shipped without a name. You must also select the desired parameter
values.

Page 24 RES-5010 Version 4

Device functions

8.4 Communication protocol

The communication protocol consists of 2x16 bit input words and 3x16 bit output words (from the point of view of
the controller). This protocol separates the set point and the actual value of the RES-5010 from the status infor-
mation and the control functions, to simplify decoding by the PROFINET controller.
Bits 0…7 form the low byte and bits 8…15 the high byte ("INTEL format").
The 2 x 16-bit input data contains the set point in word  and the control functions in word :

 Spare Set point / AC temperature

Name: 0 0 0 0 0 0 0
Bit no.: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

 Spare Channel Spare Control function

Name: 0 0 0 0 0 CH2 CH1 CH0 0 0 KS1 MA MP RS ST AC

Bit no.: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1. As from firmware version 312

The 3 x 16-bit output data contains the actual value in word , the status information in word , and the error
code in word :

 Actual value (signed)

Name:
Bit no.: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

 Spare Channel Status information

Name: 0 0 0 MU1 CH2 CH1 CH0 SA IA WA AA AG AL TE TO RA

Bit no.: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

1. As from firmware version 303

 Error code

Name: 0 0 0 0 0 0 A9 A8 A7 A6 A5 A4 A3 A2 A1 A0
Bit no.: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

If the optional "Temperatures" submodule has been configured, the controller returns another 16-bit output word
with the start temperature:

 Start temperature (signed)

Name:
Bit no.: 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

Version 4 RES-5010 Page 25

 Device functions

8.5 Input data

The term "input data" refers to the data that is transferred from the PROFINET controller to the RES-5010. It con-
tains the set point as well as the control functions such as START or AUTOCAL for the RES-5010. These functions
are explained in the following.
If the PROFINET controller marks its output data with the IOPS "bad" or does not transmit any data at all, all bits
are set to 0 (inactive). An active heatsealing process is interrupted.

8.5.1 Automatic zero calibration AUTOCAL (AC)

Owing to the automatic zero calibration (AUTOCAL) function, there is no need to adjust the zero point manually
on the controller. This function adjusts the controller to the current and voltage signals present in the system and
calibrates it to the value which is predefined in the parameter data ( section 8.7.5 "Variable calibration tempera-
ture" on page 36). If no parameter data is transferred by the PROFINET controller, the default value is 20 °C.
Some PROFINET controllers do not allow the parameter data to be changed during operation. In this case, the
calibration temperature cannot be adapted to the actual ambient conditions in the machines.
The calibration temperature can thus be specified by means of the "Set point / AC temperature" input data when-
ever the zero point is calibrated, provided this is permitted in the parameter data ( section 8.7.5 "Variable cali-
bration temperature" on page 36). You can specify it in the 0…+40 °C range. The specified calibration temperature
must be entered in the "Set point / AC temperature" input data when the AUTOCAL function is activated
(AC bit = 1). This specified value must not be changed until the AUTOCAL function has finished.
If the specified temperature is too high (greater than 40 °C) or if the specified value fluctuates, an error message
appears (error codes 115 and 116;  section 8.19 "Error messages" on page 50).
The AUTOCAL request (AC bit = 1) is executed by the controller provided the AUTOCAL function is not blocked.
The automatic calibration takes around 10…15 seconds. The heatsealing band is not heated during this process.
The yellow LED on the front panel lights up while the AUTOCAL function is executing and the controller shows
"AUTOCAL active" (AA bit = 1) in the output data. The actual value output (terminals 17+18) changes to 0…3 °C
(corresponds to approx. 0 VDC).
If the temperature of the heatsealing band fluctuates, the AUTOCAL function is executed a maximum of three
times. If the function still cannot be executed successfully, an error message appears ( section 8.19 "Error mes-
sages" on page 50).
The AUTOCAL function should only be activated while the heatsealing band (and the environment, i.e. silicone,
PTFE cover, sealing bar etc.) is still cold (base temperature).

Reasons for blocked AUTOCAL function:

1. An AUTOCAL request cannot be accepted until 10 seconds after the controller is switched on. During this time
the controller shows "AUTOCAL blocked" (AG bit = 1) in the output data.
2. The AUTOCAL function is not activated if the heatsealing band cools down at a rate of more than 0.1 K/s. If
the AC bit is set, the function is automatically executed when the cooling rate falls below the specified value.
3. If the START bit is set (ST bit = 1), the AUTOCAL function is not executed ("HEAT" LED lit).
4. If the RESET bit is set (RS bit = 1), the AUTOCAL function is not executed.
5. The AUTOCAL function cannot be activated if error codes 101…103, 201…203 or 9xx appear as soon as the
controller is switched on ( section 8.19 "Error messages" on page 50). It also cannot be activated if error
codes 201…203 or 9xx appear and the controller has operated correctly at least once since being switched on.
If the AUTOCAL function is blocked (AG bit = 1), an AUTOCAL request (AC bit = 1) causes the "AUTOCAL" LED
to blink fast (4 Hz).

8.5.2 Start (ST)

When the START bit is set (ST bit = 1), the controller’s internal set / actual comparison is enabled and the heat-
sealing band is heated to the SET temperature. It remains at this temperature either until the ST bit is reset or until
the actual heating time exceeds the preset heating time limit ( section 8.7.6 "Heating time limit" on page 36).

Page 26 RES-5010 Version 4

Device functions

The "HEAT" LED on the front panel of the RES-5010 lights up continuously for the duration of the heating time.
A start request is not processed as long as the AUTOCAL function is active, a fault is present on the controller,
the set point is less than 20 °C higher than the calibration temperature, or the RS bit is set. In this case, the "HEAT"
LED blinks.
The heatup process is terminated if the ST bit is reset or if a communication error occurs.
The ST bit is only accepted if the AUTOCAL function is deactivated and there are no faults.
The alarm relay is switched if the ST bit is set while a warning with error code 104…106, 111…114, 211, 302, or
303 is indicated ( section 8.19 "Error messages" on page 50). The heating element is not heated.

8.5.3 Reset (RS)

This bit resets the controller if the controller shows a fault.
No AUTOCAL or START requests are accepted as long as the RS bit is set. Until it is reset again, only error codes
201…203, 901, 913 are evaluated and output by the error diagnosis function. The power unit is not activated in
this state and no measuring impulses are generated. As a result of this, the actual value is no longer updated. The
reset request is not accepted until the RS bit is reset. PROFINET communications are not interrupted by a con-
troller reset.
The controller actual value output changes to 0…3 °C (i.e. approximately 0 VDC) and the SA bit is set in order to
set the RS bit.
The AUTOCAL function is not canceled if the RS bit is set while it is executing.
The controller performs an internal initialization lasting approximately 500 ms after the RS bit is reset. The next
heatsealing process cannot be started until it has finished.
If a Kb contactor is used to deactivate the control loop ( section 6.3 "Power supply" on page 12), it must be reli-
ably energized again 200 ms at the latest after the RS bit is reset (note the contactor switching and delay times).
If it is energized too late, an error message appears on the controller.

8.5.4 Measurement pause (MP)

No more measuring impulses are generated by the controller as soon as the MP bit is set. Until it is reset again,
only error codes 5 and 7 (201…203, 901, 913) are evaluated and output by the error diagnosis function. In addi-
tion, the actual value is no longer updated. The last valid value before the MP bit was set is output. As soon as the
MP bit is reset, new measuring impulses are generated, all error messages are evaluated, and the actual value is
updated again.
The MP bit is only active in measurement mode. The bits ST, RS, and AC take priority.
The bit is suitable for all applications in which the electrical connections of the heatsealing band must be discon-
nected during normal operation without triggering a fault (e.g. sliding rail contacts).
Unlike the RS bit (RESET), the MP bit does not reset any faults when it is set. The controller is active again as
soon as the MP bit is reset, in other words there is no initialization phase.
When the controller is switched on, it does not evaluate the MP bit until the system test (including the functional
test of the heating circuit) has been successfully completed. This can take several hundred milliseconds.

8.5.5 Master AUTOCAL (MA)

Setting this control bit starts a calibration as described in section 8.5.1 "Automatic zero calibration AUTOCAL
(AC)" on page 26. However, if the Master AUTOCAL function is successful, the heatsealing band resistance which
is determined by the controller is also used as a reference value, e.g. after replacing the heatsealing band.
This reference value serves to calculate the deviation from the calibration value for all subsequent calibrations (ini-
tiated with the AC bit). This deviation helps you assess aging of the heatsealing band.
The deviation from the calibration value is queried by means of acyclic read accesses to the optionally configurable
"Calibration deviation" module.

Version 4 RES-5010 Page 27

 Device functions

8.5.6 Constant regulation ratio (KS)

This bit is first available as from firmware version 312.

!
By activating this control bit, a constant power output level is provided. If the KS bit is activated, no temperature
control takes place.

Large output values lead to a very rapid temperature rise of the heatsealing band and possibly to
! overheating. Temperature diagnostics should be activated to detect a temperature overshoot and
trigger an error.

The power output level must be specified in the setpoint as a percentage of the maximum power at the time the
KS bit is activated. The permissible value range is 0…100%. For larger values, a limitation to 100% takes place.
The power setting level must be determined by sealing tests. The machine must operate under real conditions.
When determining the output level, it is recommended to start with 10% and to increase the value in small steps.

8.5.7 Channel selection (CH0…CH2)

The temperature controller has separate memories for up to eight calibration data records. A calibration data
record contains the values determined by the temperature controller during the AUTOCAL function. By storing the
calibration data records, you can alternate between different sealing tools without having to run the AUTOCAL
function every time the tool is changed. You only need to execute AUTOCAL if you connect a new heatsealing
band.
Since different calibration values, AUTOCAL temperatures, and temperature coefficients are stored in the con-
troller for this purpose, the required calibration data record 0…7 can be selected with the three bits CH0…CH2.
You can switch to another channel at any time.
This function is useful, for instance, in applications where frequent changes of format are necessary. The tools
can then be changed as required in order to handle the different formats. A channel containing the relevant cali-
bration data record is assigned to each tool. Once all tools have been calibrated with a unique channel assign-
ment, they can be changed at any time simply by selecting the appropriate channel.
If the application does not require any format changes, the channel can remain set to 0. In this case, the tempera-
ture controller behaves in exactly the same way as older models where different calibration data records are not
supported.
It is possible to switch to another channel during the AUTOCAL function; however, the controller continues working
with the original channel until the AUTOCAL function has finished. The channel currently being used by the con-
troller is shown in the status information.

8.5.8 Set point

A set point of up to 300 °C or 500 °C is allowed, depending on the selected temperature range ( section 8.7.1
"Temperature range and alloy" on page 35). If you attempt to enter a higher set point, it is limited internally to
300 °C or 500 °C.
When constant output operation is activated (KS bit = 1), the setpoint determines the amount of the constant
output in the range 0...100%.

8.6 Output data

The term "output data" refers to the data that is transferred from the RES-5010 to the PROFINET controller. It con-
tains the current actual value as well as all important information on the current status of the controller. If a fault is
signaled, it can be diagnosed accurately with the help of the error code.

Page 28 RES-5010 Version 4

Device functions

8.6.1 AUTOCAL active (AA)

The AA bit indicates that the AUTOCAL or AUTOCOMP function is executing.

8.6.2 AUTOCAL blocked (AG)

If the AG bit is set, the AUTOCAL function is temporarily blocked. This is the case if "START" is active or the heat-
sealing band is still in the cooling phase.

8.6.3 Alarm active (AL)

If the AL bit is set, an alarm has been triggered but not yet reset. The error code provides information on the exact
cause ( section 8.19 "Error messages" on page 50).

8.6.4 Warning active (WA)

This bit can be set in addition to the AL bit. If the WA bit is set, a warning is output to indicate the current fault. In
this case, the alarm relay is not active.

8.6.5 Temperature achieved (TE)

The TE bit is set if the actual temperature exceeds 95% of the set temperature. This status bit is reset again as
soon as you exit control mode (ST bit = 0) or a fault is signaled (AL bit = 1).

8.6.6 Temperature OK (TO)

The RES-5010 checks whether the actual temperature is within a settable tolerance band ("OK" window) either
side of the set temperature. The high ( Δϑ high ) and low ( Δϑ low ) limits of the tolerance band can be changed inde-
pendently of one another in the parameter data ( section 8.7 "Parameter data" on page 31). The following set-
tings are possible:
1. "Off"
The TO bit is always reset.
2. "Active when Tact = Tset" (factory setting)
The TO bit is set if the actual value is inside the specified temperature tolerance band. If the actual temperature
is outside of the tolerance band, the TO bit is reset (see graph below).

Actual value
Set+ Δϑ high

Set

Set+ Δϑ low

Time
TO bit
1
0
Time

Unlike the "Temperature achieved" status bit (TE bit), the actual temperature is evaluated independently of the
control mode.
3. "Active when Tact = Tset" with latch function
A heatsealing cycle starts when the ST bit is set. The TO bit is set when the actual temperature reaches the

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temperature tolerance band for the first time during a heatsealing cycle. If the actual temperature leaves the
tolerance band again while the ST bit is still set, the TO bit is reset (Fig. a.). If the actual temperature does not
leave the tolerance band while the ST bit is still set, the TO bit is not reset until the start of the next heatsealing
cycle (latch function, Fig. b.). The switching state of the TO bit can thus be queried after the ST bit has been
reset and before the start of the next heatsealing cycle.

a.) Temperature not ok b.) Temperature ok

Actual value Actual value
Set+ Δϑ high Set+ Δϑ high

Setpoint Setpoint

Set+ Δϑ low Set+ Δϑ low

Time Time
ST bit 1 ST bit 1
0 0
Time Time
TO bit 1 TO bit 1
0 0
Time Time

The limits of the tolerance band are adjustable up to a maximum of ±99 K.

!

8.6.7 Control active (RA)

The RES-5010 has successfully accepted the "START" request and entered control mode if the RA bit = 1.

8.6.8 Info active (IA)

This bit is reserved for future use and is not currently supported (it is always set to 0).

8.6.9 Standby active (SA)

This bit is active if the RS bit is set. It shows the PLC when the controller has accepted the RS bit or the MP bit,
so that these bits can be reset again (handshake).

8.6.10 Measurement interruption (MU)

This bit is available as from firmware version 303.

!
This bit is active as long as the controller does not perform a temperature measurement during the regulation
phase (ST = 1). This can occur when the actual value is larger than the setpoint value (setpoint exceeded). This
can be used, for example, to evaluate whether measurement interruptions occur during the heating impulse. This
would then be an indication of excessive temperature, which can result in a bad sealing seam.
As soon as a measurement is performed again, the MU bit goes back to 0.
The maximum duration of the measurement interruption can be parameterized on the RES-5010
( section 8.7.15 "Maximum measurement pause" on page 41).

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8.6.11 Actual value

All 16 bits of the first word must be interpreted as a signed number (twos complement notation). The resolution is
1 °C. During the calibration procedure or if a fault occurs, the actual value is 0.

8.6.12 Start temperature

If the optional "Temperatures" submodule has been configured, the controller returns another 16-bit output word
with the last start temperature. This is the temperature which was measured just before the start command was
executed (ST bit = 1). This value allows you to evaluate the cooling process. It is only valid during the heating
phase (ST bit = 1). Outside of this phase the value "-99 °C"appears, so that it is possible to distinguish between
valid and invalid values. The normal value range is between -20 °C and 500 °C.

8.6.13 Error codes

If a fault is signaled (AL bit = 1), you can determine the exact cause with the help of the error code. The error code
is contained in the third word at bit positions 0…9 ( section 8.19 "Error messages" on page 50).
In addition to the error codes, the PROFINET diagnosis function also sends error messages to the PROFINET
controller. The error messages corresponding to each error code are already stored in the device master file
(GSDML), so that they automatically appear in plain text on the PROFINET controller when a device diagnosis for
the RES-5010 is requested there. The error messages are stored in the GSDML file in English and German. You
can select the language in the configuration tool.

8.7 Parameter data

The parameter data contains values for selecting the heatsealing band alloy, the temperature range, the high and
low tolerance limits for temperature monitoring, the calibration temperature, and the optional heating time limit. It
is transferred from the PROFINET controller to the RES-5010 each time the system is started up. The parameters
can also be queried by the PROFINET controller or transmitted by it to the RES-5010 controller at any time using
asynchronous read / write services. They are not stored in the RES-5010. The parameter data can be addressed
at slot 1, subslot 1, starting at index 4. It has the following structure:

Index 46 to index 48 are first available as from firmware version 312.

!

Index Function Default value1 Value range

4 Temperature range / alloy 10 0, 1, 4, 5, 8, 10, 11

( 8.7.1)

5 Low temperature OK threshold 10 K 3…99 K

6 High temperature OK threshold 10 K 3…99 K

7 Calibration temperature 20 °C -1, 0…40 °C

8/9 Heating time limit (100 ms steps) 0 0…999

(0…99.9 s)

10 External module / channel errors On Off (0), on (1)

11 Measuring impulse duration 17 17…30

(1.7…3.0 ms)

12 Data format Little Endian (Intel) Little Endian (Intel) (0),

Big Endian (Motorola) (1)

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Index Function Default value1 Value range

13/14 Temperature coefficient 1100 ppm/K 400…4000 ppm/K

15 Temperature range 300 °C 200 °C (0), 300 °C (1),

400 °C (2), 500 °C (3)

16/17 Maximum temperature 300 °C 200…500 °C

18 Temperature diagnosis Off Off (0), on (1)

19 Temperature diagnosis delay (100 ms 0s 0…99

steps) (0…9.9 s)

20/21 Heatup timeout 0s 0…999

(100 ms steps) (0…99.9 s)

22 AUTOCOMP Off Off (0), on (1), auto (2)

23 Temperature OK bit Off (0),

Active when Tact=Tset active when Tact=Tset (1),
active when Tact=Tset
with latch (2)

24 Hold mode Off Off (0), on (1), 2 s (2)

25 Calibration temperature, channel 1 20 °C -1, 0…40 °C

26/27 Temperature coefficient, channel 1 1100 ppm/K 400…4000 ppm/K

28 Calibration temperature, channel 2 20 °C -1, 0…40 °C

29/30 Temperature coefficient, channel 2 1100 ppm/K 400…4000 ppm/K

31 Calibration temperature, channel 3 20 °C -1, 0…40 °C

32/33 Temperature coefficient, channel 3 1100 ppm/K 400…4000 ppm/K

34 Calibration temperature, channel 4 20 °C -1, 0…40 °C

35/36 Temperature coefficient, channel 4 1100 ppm/K 400…4000 ppm/K

37 Calibration temperature, channel 5 20 °C -1, 0…40 °C

38/39 Temperature coefficient, channel 5 1100 ppm/K 400…4000 ppm/K

40 Calibration temperature, channel 6 20 °C -1, 0…40 °C

41/42 Temperature coefficient, channel 6 1100 ppm/K 400…4000 ppm/K

43 Calibration temperature, channel 7 20 °C -1, 0…40 °C

44/45 Temperature coefficient, channel 7 1100 ppm/K 400…4000 ppm/K

46/47 Restart delay after Reset (100 ms 0.2 s 0…999

steps)2 (0…9.99 s)

48 Maximum measurement pause 10 0...10

2
[periods]
1. The default value is stored in the device master file (GSDML) and transferred from the PROFINET con-
troller to the RES-5010 when the system is started up.
2. As from firmware version 312

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The date, time, operating hours counter, and counters for the individual calibration channels can be read out at
slot 1, subslot 2. Apart from the operating hours counter (index 4…7) and the non-clearable total cycle counter
(index 8…11), these counters can also be reset by means of a write access.
A plausibility check which takes account of leap years is performed after writing the date or time. If the transferred
values do not contain any valid date or time information, the RES-5010 responds with an access error: 0xb7
"Invalid Range". To prevent inconsistencies, the individual date or time values should be changed together with a
single write access, in other words index 0…3 and 4…7.

Index Function Default value Value range

0 Date: Day 1…31

1 Date: Month 1…12

2/3 Date: Year 2000…2099

4 Time: Milliseconds (not used)1 0 0…99

5 Time: Seconds 0…59

6 Time: Minutes 0…59

7 Time: Hours 0…23

8…11 Operating hours (in 0.1 h) 0.0 h 0…99999999.9 h

12…15 Non-clearable total cycle counter 0 0…999999999

16…19 Clearable total cycle counter 0 0…999999999

20…23 Cycle counter, channel 0 0 0…999999999

24…27 Cycle counter, channel 1 0 0…999999999

28…31 Cycle counter, channel 2 0 0…999999999

32…35 Cycle counter, channel 3 0 0…999999999

36…39 Cycle counter, channel 4 0 0…999999999

40…43 Cycle counter, channel 5 0 0…999999999

44…47 Cycle counter, channel 6 0 0…999999999

48…51 Cycle counter, channel 7 0 0…999999999

1. Milliseconds are not supported by the internal real-time clock. Read accesses always return 0. A value
in the range 0…99 must be transferred during write accesses or the RES-5010 will respond with an
access error: 0xb7 "Invalid Range".

The start temperature ( section 8.6.12 "Start temperature" on page 31) and the internal device temperature are
available at slot 1, subslot 3. They are read-only values which cannot be written,

Index Function Default value Value range

0/1 Start temperature -99 °C -99…500 °C

2/3 Device temperature -60…190 °C

The channel-specific deviations from the calibration data are available at slot 1, subslot 4 ( section 8.5.5 "Master
AUTOCAL (MA)" on page 27). They are read-only values which cannot be changed. The absolute calibration

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resistances are available from index 17. At index 16 the value of the passes through the current transformer is
available. This value can also be written and will be stored retentively in the controllers memory with every change.
The correct calculation of the absolute calibration resistances is only possible if the real count of wire passes
through the current transformer is given in this parameter.

The indices 16 to 48 are first available as from firmware version 303.

!

Index Function Default value Value range

0/1 Calibration deviation, channel 0 (in 0.01%) 0 -100.00%…100.00%

2/3 Calibration deviation, channel 1 (in 0.01%) 0 -100.00%…100.00%

4/5 Calibration deviation, channel 2 (in 0.01%) 0 -100.00%…100.00%

6/7 Calibration deviation, channel 3 (in 0.01%) 0 -100.00%…100.00%

8/9 Calibration deviation, channel 4 (in 0.01%) 0 -100.00%…100.00%

10/11 Calibration deviation, channel 5 (in 0.01%) 0 -100.00%…100.00%

12/13 Calibration deviation, channel 6 (in 0.01%) 0 -100.00%…100.00%

14/15 Calibration deviation, channel 7 (in 0.01%) 0 -100.00%…100.00%

16 Passes through current transformer 1 1…9

17/18 Calibration resistance, channel 0 (in 0.1 mΩ) 0 0…6553.5 mΩ

19/20 Calibration resistance, channel 1 (in 0.1 mΩ) 0 0…6553.5 mΩ

21/22 Calibration resistance, channel 2 (in 0.1 mΩ) 0 0…6553.5 mΩ

23/24 Calibration resistance, channel 3 (in 0.1 mΩ) 0 0…6553.5 mΩ

25/26 Calibration resistance, channel 4 (in 0.1 mΩ) 0 0…6553.5 mΩ

27/28 Calibration resistance, channel 5 (in 0.1 mΩ) 0 0…6553.5 mΩ

29/30 Calibration resistance, channel 6 (in 0.1 mΩ) 0 0…6553.5 mΩ

31/32 Calibration resistance, channel 7 (in 0.1 mΩ) 0 0…6553.5 mΩ

33/34 Initial calibration resistance, channel 0 (in 0.1 mΩ) 0 0…6553.5 mΩ

35/36 Initial calibration resistance, channel 1 (in 0.1 mΩ) 0 0…6553.5 mΩ

37/38 Initial calibration resistance, channel 2 (in 0.1 mΩ) 0 0…6553.5 mΩ

39/40 Initial calibration resistance, channel 3 (in 0.1 mΩ) 0 0…6553.5 mΩ

41/42 Initial calibration resistance, channel 4 (in 0.1 mΩ) 0 0…6553.5 mΩ

43/44 Initial calibration resistance, channel 5 (in 0.1 mΩ) 0 0…6553.5 mΩ

45/46 Initial calibration resistance, channel 6 (in 0.1 mΩ) 0 0…6553.5 mΩ

47/48 Initial calibration resistance, channel 7 (in 0.1 mΩ) 0 0…6553.5 mΩ

Slot 1, subslot 5 contains the elements required for the TCR Calculator ( section 8.7.2 "TCR Calculator" on
page 35). The external measured temperature is writable, the calculated temperature coefficient is read-only.

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Slot 1, subslot 5 is first available as from firmware version 312.

!

Index Function Default value Value range

0/1 External measured temperature 40 40…600 °C

2/3 Calculated temperature coefficient 0 400…4000 ppm/K

0 (error), 65535 (error)

8.7.1 Temperature range and alloy

This parameter determines both the temperature range and the heatsealing band alloy. You can overwrite the set-
ting of the rotary coding switch ( section 7.2.2 "Configuration of the rotary coding switch for the temperature
range and alloy" on page 18) by changing the default value (10).

Value Temperature range Alloy

0 300 °C TCR = 1100 ppm/K, e.g. Alloy A20

1 300 °C TCR = 780 ppm/K, e.g. Alloy L

4 500 °C TCR = 1100 ppm/K, e.g. Alloy A20

5 500 °C TCR = 780 ppm/K, e.g. Alloy L

8 300 °C TCR = 3500 ppm/K, e.g. LEX3500

9 PC setting (visualization software) PC setting (visualization software)

10 Rotary coding switch setting Rotary coding switch setting

11 Variable: Parameter index 15 is used Variable: Parameter index 13/14 as well as the
channel-specific temperature coefficients at
index 26/27, 29/30, 32/33, 35/36, 38/39, 41/42,
44/45 are used

You must always execute the AUTOCAL function after changing the "Temperature range / alloy", "Temperature
range", or "Temperature coefficient" parameter.

8.7.2 TCR Calculator

This functionality is first available as from firmware version 312.

!
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-
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.
To calculate the TCR value, the temperature at the heatsealing band is measured in control mode (ST bit = 1)
using an external temperature sensor (e.g. a thermocouple). The measured temperature is transferred to the tem-
perature controller in slot 1, subslot 5, Index 0/1. The calculated temperature coefficient can be read out from
slot 1, subslot 5, Index 2/3. The temperature coefficient is only calculated in control mode (ST bit = 1). 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.

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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 calculated TCR value, it must be set for the corresponding channel as temperature coefficient in param-
eter index 13/14, 26/27, 29/30, 32/33, 35/36, 38/39, 41/42 or 44/45 (temperature coefficient). In addition, the
value 11 (variable) must be used in parameter index 4 (alloy / temperature range).

8.7.3 Low temperature OK threshold

Low threshold value for the "OK" window.
Refer to section 8.6.6 "Temperature OK (TO)" on page 29 and section 8.7.11 "Temperature diagnosis" on
page 38.

8.7.4 High temperature OK threshold

High threshold value for the "OK" window.
Refer to section 8.6.6 "Temperature OK (TO)" on page 29 and section 8.7.11 "Temperature diagnosis" on
page 38.

8.7.5 Variable calibration temperature

The calibration temperature is set to 20 °C by default. You can change it to another value between 0 °C and 40 °C
in order to adapt it to the temperature of the cold heatsealing band.
Some PROFINET controllers do not allow the parameter data to be changed during operation. In this case, the
calibration temperature cannot be adapted to the actual ambient conditions in the machines.
The calibration temperature can thus be enabled for setting by means of the input data by specifying the value "-1"
in the parameter data. The calibration temperature can then be specified via the "Set point / AC temperature" input
data ( section 8.5.1 "Automatic zero calibration AUTOCAL (AC)" on page 26).
After a change of the calibration temperature, the AUTOCAL function must be performed.

8.7.6 Heating time limit

The heating time limit provides additional protection against unwanted continuous heating. The controller auto-
matically deactivates the heating impulse after the set heating time limit has elapsed if the ST bit remains set for
longer than the time specified with this limit. The ST bit must be reset before the controller can be started up again.
The heating time limit is deactivated by default (0) but can be set to any value between 0 s and 99.9 s (0 and 999).

8.7.7 External module / channel errors

The device diagnosis uses the diagnostic channel of the PROFINET protocol to display any RES-5010 errors
directly on the PROFINET controller. There is a text message stored in the device master file (GSDML) for each
error which is automatically displayed in plain text on the PROFINET controller, provided the controller has this
capability.
The display of external module / channel errors can be activated or deactivated by means of the parameter at
index 8. The default setting for external module / channel errors is "on".
You can check the controller status by means of the user data regardless of this parameter.

8.7.8 Measuring impulse duration

The length of the measuring impulses generated by the controller can be set with this parameter. It may be nec-
essary to set a measuring impulse longer than the default 1.7 ms for certain applications.

8.7.9 Data format

This parameter specifies the order of the bytes ("Little Endian (Intel)” or "Big Endian (Motorola)") in the cyclic data;
this setting applies to both input and output data ( section 8.4 "Communication protocol" on page 25).

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Device functions

We recommend selecting "Big Endian (Motorola)" for Siemens PLCs.

!

8.7.10 Automatic phase angle compensation (AUTOCOMP)

It may be necessary to compensate the phase angle displacement between the UR and IR measuring signals for
specific heatsealing applications ( ROPEX Application Report). The AUTOCOMP function is provided for this
purpose. The following settings are possible:
1. "Off" (factory setting)
The AUTOCOMP function is switched off.
2. "On"
The AUTOCOMP function is executed whenever the AUTOCAL function ( section 8.5.1 "Automatic zero cal-
ibration AUTOCAL (AC)" on page 26) is executed twice in quick succession. The interval between the end of
the first AUTOCAL function and the start of the second AUTOCAL must be shorter than 2.0 seconds. The
second AUTOCAL function only takes around 2.0 seconds and includes the AUTOCOMP function.
If the interval between the two AUTOCAL functions is longer than 2.0 seconds, AUTOCAL is executed normally
again the second time.

AC bit <2.0 s
1

0
t

Function
AUTOCOMP

AUTOCAL
0
t
"AUTOCAL"
LED
Lit

Off
t

"OUTPUT"
LED
Lit

Off
t

The "OUTPUT" LED blinks several times when the AUTOCOMP function is executed and the actual value
output (terminals 17+18) changes to 0…3 °C (corresponds to approx. 0 VDC).
3. "AUTO"
This setting causes the AUTOCOMP function to be automatically activated after the AUTOCAL function has
been successfully executed.

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AC bit

0
t

Function
AUTOCOMP

AUTOCAL
0
t
"AUTOCAL"
LED
Lit

Off
t

"OUTPUT"
LED
Lit

Off
t

The "OUTPUT" LED blinks several times when the AUTOCOMP function is executed and the actual value
output (terminals 17+18) changes to 0…3 °C (corresponds to approx. 0 VDC).
The AUTOCOMP function must be activated in the parameter data ( section 8.7 "Parameter data" on page 31)
(default setting: AUTOCOMP off).

8.7.11 Temperature diagnosis

An additional temperature diagnosis can be activated in the parameter data (GSDML file). The RES-5010 checks
whether the actual temperature is within a settable tolerance band ("OK" window) either side of the set tempera-
ture. The high ( Δϑ high ) and low ( Δϑ low ) tolerance limits are the same as for the "Temperature OK" function
(TO bit  section 8.6.6 "Temperature OK (TO)" on page 29). The limits are set to -10 K and +10 K by default.
If the ACTUAL temperature is inside the specified tolerance band when the START signal is activated, the tem-
perature diagnosis is activated as well. If the ACTUAL temperature leaves the tolerance band, the corresponding
error code (307, 308) appears and the alarm relay is switched ( section 8.19 "Error messages" on page 50).

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ACTUAL temperature
Set+ Δϑ high

Set

Set+ Δϑ low

Time
Error code
307

If the temperature diagnosis is not activated by the time the START signal is deactivated (i.e. if the ACTUAL tem-
perature does not exceed the high or low tolerance band limit), the corresponding error code (309, 310) appears
and the alarm relay is switched.
An additional delay time (0..9.9 s) can be set in the parameter data (GSDML file). The first time the low tolerance
limit is exceeded, the temperature diagnosis is not activated until the configured delay time has elapsed. The tem-
perature diagnosis function can thus be selectively deactivated, e.g. if the temperature drops temporarily owing to
the closure of the sealing jaws.
The high and low tolerance limits cannot be set in the ROPEX visualization software. The same limits apply as
with the TO bit. They can only be set in the parameter data ( section 8.7 "Parameter data" on page 31).

8.7.12 Heatup timeout

An additional heatup timeout can be activated in the parameter data (GSDML file).
This timeout starts when the ST bit is set. The RES-5010 then monitors the time required for the ACTUAL tem-
perature to reach 95% of the SET temperature. If this time is longer than the configured time, the corresponding
error code (304) appears and the alarm relay is switched ( section 8.19 "Error messages" on page 50).

ACTUAL temperature

Set
95% of set

Time-
out

Time
Heatup time Error code
304

The "Heatup timeout" function must be enabled for use in the parameter data ( section 8.7 "Parameter data" on
page 31) (default setting: heatup timeout off).

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8.7.13 Hold mode

The ACTUAL temperature output via the PROFINET protocol can be configured in the parameter data (GSDML
file) as follows:
1. "Off" (factory setting)
The ACTUAL temperature is always output in real time.
2. "On"
The ACTUAL temperature that was valid at the end of the last heatsealing phase is output. When the controller
is switched on, the real ACTUAL temperature is indicated up until the end of the first heating phase.
3. "2 sec."
This setting causes the current ACTUAL temperature to be output for an additional 2 seconds by means of the
PROFINET protocol at the end of a heatsealing phase. The ACTUAL temperature is then output again in real
time until the end of the next heatsealing phase.
Hold mode only applies to the ACTUAL temperature which is output via the PROFINET protocol and the digital
temperature display in the ROPEX visualization software. It has no effect on the ACTUAL temperature that
appears at the controller’s analog output or is plotted in the graphics window of the ROPEX visualization software.
The various hold modes are shown below:

ST bit

0
ACTUAL t
temperature
T

0
t
ACTUAL indication

Hold off
T

0
t
Hold on Hold Hold
T

0
t
Hold 2 s Hold Hold
T

0
t
2s 2s
End of
heatsealing phase

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The "Hold mode" function must be activated in the parameter data ( section 8.7 "Parameter data" on page 31)
(default setting: hold mode off).

8.7.14 Restart delay after Reset

This element is first available as from firmware version 312.

!
After acknowledging an alarm with the reset signal (RS bit), the RESISTRON® temperature controller waits until
any contactor connected has closed the heating circuit again. Only after this waiting time has elapsed measuring
pulses are generated again in order to determine the current ACTUAL temperature and to carry out error diagnos-
tics. This restart delay is 0.2 s by default and can be adjusted with the parameter index 46/47. This allows slower
switching contactors to be used.

8.7.15 Maximum measurement pause

This element is first available as from firmware version 312.

!
If the RESISTRON® temperature controller determines in control mode (ST bit = 1), that the current ACTUAL tem-
perature 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 temperature, are paused.
This measurement pause can last up to 10 periods in the default setting. During this measurement pause, the con-
troller cannot react to a change in the ACTUAL temperature. The status bit „measurement interruption active“
( section 8.6.10 "Measurement interruption (MU)" on page 30) is active (MU bit = 1) at this time.
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 this case the maximum measuring pause can be
shortened with the parameter index 48.

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.

8.8 Integrated web server

The integrated web server enables quick and easy access to status information and parameter values of the tem-
perature controller via the existing Ethernet connection. The device protocol can additionally be read out and dis-
played. A graph showing the last 5 seconds of a heating impulse allows a rapid qualitative evaluation of the con-
trolled system.
The latest version of the operating instructions can be downloaded from the ROPEX website by clicking on the
picture of the device on any page. To make sure this latest version is always available in any selectable language,
the instructions are not stored in the device; you must therefore have an Internet connection in order to access the
operating instructions.
You can go direct to the official ROPEX website by clicking on the ROPEX logo in the top right-hand corner.
The web server uses JavaScript and has been successfully tested with Internet Explorer 9, 10, and 11 as well as
with Microsoft Edge. It also works with the latest version of the Safari and Firefox browsers.

8.8.1 Home page

This page contains general product information under "Device Information", for instance the product name, serial
number, firmware version, MAC address, and real-time Ethernet protocol. You can also download the correct

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device description file for your product here ( section 8.3 "Device master file (GSDML)" on page 24). No Internet
connection is necessary to do this because the file is already stored in the device’s internal memory.

8.8.2 Status page

This page provides an overview of the current controller status.
"Online" indicates whether a connection has been set up to the PLC.
The inputs ( section 8.5 "Input data" on page 26) are shown in the left-hand column, the outputs ( section 8.6
"Output data" on page 28) in the middle column, and the current status of all device LEDs ( section 8.1 "LEDs
and controls" on page 22) in the right-hand column.

8.8.3 Parameters / Counters page

This page shows all parameter values received by the temperature controller from the PROFINET controller. If the
parameters have been changed using acyclic services, these changes are also indicated here.
For the meanings of the parameter data, refer to section 8.7 "Parameter data" on page 31.

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Under "Counters" you see a list of all cycle and operating hours counters, which are useful for statistical purposes.

8.8.4 Protocol page

You can download and display the device protocol for the temperature controller on this page. You see the overall
size of the protocol ("Total event entries") as well as the upload progress. All entries appear in the form of a table.
A timestamp (generated by the built-in clock), the operating hours and cycle counters, and the channel selected
at the time are shown for each entry.
In addition to errors, the protocol also contains entries of general interest such as "Clock set" or the AUTOCAL
function. An error code provides information on the cause of all events in the protocol. The error codes are
described in detail in section 8.19 "Error messages" on page 50. Each error code is explained in a tooltip when
you hover over it briefly.
The data can also be exported to a CSV file to enable further processing in another software program. By clicking
on the appropriate button you can select a comma separated format or a semicolon separated format.

The download may take a few seconds, depending on the number of entries which are stored here. The newest
events appear at the top of the list.

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If any new events occur while this page is displayed, you do not see them until you refresh the list by clicking on
the "Protocol" menu again.

8.8.5 Graphic page

The temperature controller has an internal memory which can store temperature curves over a period of up to
5 seconds. This memory is automatically filled when the ST bit is set. You can display or export the memory con-
tents on the Graphic page.
By clicking on "Refresh", you cause the graphic data to be downloaded from the memory of the temperature con-
troller and displayed again.
"Clear" clears all data from the memory (disconnecting the 24 VDC supply voltage has the same effect).

The vertical lines mark the beginning of a new heatsealing impulse (ST bit set). A negative set point indicates the
start of a new impulse in the exported data. Cooling processes are not normally visible because they take place
when the ST bit is reset.

8.8.6 Calibration page

This page is first available as from firmware version 303.

!
The temperature controller stores the absolute calibration resistance of each channel (Calibration resistance ch.
0…7) with an resolution of 0.1 mΩ.
The calculation of the respective calibration resistance is done at the end of the AUTOCAL function
( section 8.5.1 "Automatic zero calibration AUTOCAL (AC)" on page 26).
The initial calibration resistances (Initial calibration resistance ch. 0…7) are calculated if the Master-AUTOCAL
function is executed ( section 8.5.5 "Master AUTOCAL (MA)" on page 27).

Page 44 RES-5010 Version 4

Device functions

These initial calibration resistances are the basis for the calculation of the calibration deviation. Each execution of
the AUTOCAL function will calculate both, the absolute calibration resistance and likewise the percentual calibra-
tion deviation towards the initial calibration resistance.

These values are displayed on the Calibration page.

Additionally the actual value of „passes through current transformer“ are displayed. This value can be read or
written by means of acyclic services. Set this value to the real wire passes through the current transformer for that
the absolute resistance values can be calculated correctly. This value has no influence on the calculation of the
percentual calibration deviation.

The calculation of the absolute resistance values is liable to variation and imprecision due to toler-
! ances in production, to application dimensioning, to quality of cabling, to fluctuations in the power
supply, etc.

8.9 Undervoltage detection

Trouble-free operation of the temperature controller is guaranteed within the line voltage and 24 VDC supply
voltage tolerances specified in section 10 "Technical data" on page 56.
If the 24 VDC supply voltage drops below the permitted lower limit, the controller is switched to standby mode. No
more heatsealing processes take place and no more measuring impulses are generated. Normal operation is
resumed when the input voltage returns to the specified tolerance range again.
Standby mode is indicated by 0…3 °C (i.e. approx. 0 V) at the analogue output. In addition, the SA bit is set in the
status word for the cyclic output data.

Trouble-free operation of the controller is only guaranteed within the specified tolerance range of
! the input voltage. An external voltage monitor must be connected to prevent low line or 24 VDC
supply voltage from resulting in defective heatseals.

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 Device functions

8.10 Temperature meter (actual value output)

The RES-5010 supplies an analog 0…10 VDC signal, which is proportional to the real ACTUAL temperature, at
terminals 17+18.

RES-5010

Actual value Max. 5 mA

output 17
0…10 VDC

0V 18

0…10 VDC

Temperature
meter
e.g. ATR-3

Voltage values:
0 VDC  0 °C
10 VDC  300 °C or 500 °C, depending on the device configuration
The relationship 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“

Page 46 RES-5010 Version 4

Device functions

An indicating instrument can be connected to this output in order to visualize the temperature of the heatsealing
band.
The ROPEX ATR-x temperature meter is optimally adapted to this application in every respect (size, scale,
dynamic behavior) and can be used for this, if needed ( section 6 "Mounting and installation" on page 9).
The meter not only facilitates SET-ACTUAL comparisons but also enables other criteria such as the heating rate,
set point achieved within the specified time, cooling of the heatsealing band etc. to be evaluated.
The temperature meter additionally permits disturbances in the control loop (loose connections, contacting or
wiring problems) as well as any line disturbances to be observed extremely efficiently and interpreted accordingly.
The same applies if several neighbouring control loops interfere with one another.
If a fault is signalled, this analog output is used to display a selective error message ( section 8.19 "Error mes-
sages" on page 50).

8.11 Booster connection

The RES-5010 controller has a connection for an external switching amplifier (booster) as standard. This connec-
tion (at terminals 15+16) is necessary for high primary currents (continuous current > 5 A, pulsed current > 25 A).
The booster should be connected as described in section 6.7 "Wiring diagram with booster connection" on
page 16.

The connecting cable to the booster must not be longer than 1 m; it must also be twisted in order to
! reduce EMC interference to a minimum.

8.12 USB interface for visualization software ROPEXvisual®

A USB interface (type: Micro USB) is provided for system diagnostics and process visualization. This USB inter-
face enables a data connection to be set up to ROPEXvisual®, the ROPEX visualization software.

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

The ROPEX visualization software is described in a separate document. The software and the documentation are
available in the download area (search term: “Visual”).

Version 4 RES-5010 Page 47

 Device functions

8.13 AUX interface

Internal interface for diagnostics and maintenance. This interface is not currently available.

ALARM OUTPUT DE-ENERGIZED

CONFIGURATION (AT ALARM)
ENERGIZED
AUX

0
78 9
1
2 34
6

8.14 Total cycle counter

The number of heatsealing cycles executed since the controller was shipped is stored in the internal memory
(ST bit = 1). This is a read-only counter which cannot be reset. It can be displayed in the ROPEX visualization soft-
ware ( section 8.12 "USB interface for visualization software ROPEXvisual®" on page 47), via the integrated
web server, or using the acyclic services of the PROFINET interface.

8.15 Operating hours counter

The number of operating hours since the controller was shipped is stored in the internal memory. This counter
works with a resolution of six minutes. It is a read-only counter which cannot be reset. It can be displayed in the
ROPEX visualization software ( section 8.12 "USB interface for visualization software ROPEXvisual®" on
page 47), via the integrated web server, or using the acyclic services of the PROFINET interface.

8.16 Data memory for error messages and AUTOCAL

To simplify error diagnoses during operation, the RES-5010 controller has a data memory for error messages
( section 8.19 "Error messages" on page 50) and executed AUTOCAL functions ( section 8.5.1 "Automatic
zero calibration AUTOCAL (AC)" on page 26).
The 400 most recent messages are stored. They can be read out and displayed in the ROPEX visualization soft-
ware ( section 8.12 "USB interface for visualization software ROPEXvisual®" on page 47) or via the integrated
web server.
The RES-5010 also features a built-in clock ( section 8.17 "Built-in clock (date and time)" on page 48). All mes-
sages are saved in the data memory together with their date and time of occurrence (timestamp).

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

8.17 Built-in clock (date and time)

The RES-5010 has a built-in clock. All messages are saved in the data memory ( section 8.16 "Data memory
for error messages and AUTOCAL" on page 48) together with their date and time of occurrence (timestamp). Error
messages can thus be interpreted more accurately whenever a problem needs to be analyzed.

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Device functions

The built-in clock can be set and read out in the ROPEX visualization software ( section 8.12 "USB interface for
visualization software ROPEXvisual®" on page 47) or using the acyclic services of the PROFINET interface. The
date and time can be read out but not set via the integrated server.
A maintenance-free capacitor is used to operate the clock. There is no battery that has to be replaced every now
and then.
The controller must remain switched on for at least three hours to make sure the clock’s capacitor is fully charged.
When the controller is switched off, the fully charged capacitor can keep the clock running for approximately 2…4
weeks. If the controller is switched off for longer, the date and time will have to be set again. You can do this in
the ROPEX visualization software ( section 8.12 "USB interface for visualization software ROPEXvisual®" on
page 47) or using the acyclic services of the PROFINET interface.
The capacitor is not charged when it leaves the factory. When the controller is started up, you must set the clock
if you want error messages to be saved in the data memory ( section 8.16 "Data memory for error messages
and AUTOCAL" on page 48) together with their date and time of occurrence.
The controller can also be operated without the clock. In this case, the dates and times that are saved in the data
memory will be invalid ( section 8.16 "Data memory for error messages and AUTOCAL" on page 48) . However,
this has no effect on the temperature control functions.

8.18 System monitoring / alarm output

To increase operational safety and avoid faulty heatsealing, this controller incorporates special hardware and soft-
ware features to facilitate selective error detection and diagnosis. Both the external wiring and the internal system
are monitored.
These features significantly assist the operator in identifying the cause of abnormal situations.
A system fault is reported or differentiated by means of the following indications.

A.) Red "ALARM" LED on the controller with three states:

1. Blinking fast (4 Hz):
The AUTOCAL function should be executed (error codes 104…106, 211, 302, 303).
2. Blinking slowly (1 Hz):
The system configuration is incorrect and the zero calibration (AUTOCAL function) was unsuccessful
( section 7.2 "Device configuration" on page 17). This corresponds to error codes 111…114).
3. Lit continuously:
A fault is preventing the system from starting (error codes 101…103, 107, 108, 201…203, 304, 307, 308, 9xx).
As a rule, this refers to an external wiring fault.

B.) Alarm relay (relay contact terminals 12+13+14):

This relay is set at the factory as follows:
• DE-ENERGIZED in operating states A.1 and A.2 but energized if a START signal is present in one of these
states.
• ENERGIZED in operating state A.3.

If the alarm relay has the opposite configuration to the factory setting ( section 7.2.3 "Configura-
! tion of the rotary coding switches for device names" on page 18), these states are reversed.

C.) Error code indicated via the PROFINET protocol:

If an error occurs, the AL bit is set and possibly also the WA bit. The error code is contained in the third word at
bit positions 0…9 ( section 8.6.13 "Error codes" on page 31).

D.) Error code indicated via the actual value output 0…10 VDC (terminals 17+18):
Since a temperature indication is no longer necessary if a fault occurs, the actual value output is used to display
error messages whenever a fault is signaled.

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 Device functions

Thirteen voltage levels are available for this purpose in the 0…10 VDC range, each of which is assigned an error
code ( section 8.19 "Error messages" on page 50).
For statuses that require AUTOCAL, or if the device configuration is incorrect (error codes 104…106, 111…114,
211, 302, 303), the signal at the actual value output jumps back and forth at 1 Hz between the voltage value cor-
responding to the error and the end of the scale (10 VDC, i.e. 300 °C or 500 °C). If the START signal is present in
one of these states, the voltage value does not change any more.
If a ROPEX temperature meter (e.g. an ATR-x) is connected to the controller’s analog output, the temperature
indication can be directly assigned to the error codes if an alarm is signaled.
An error message can be reset by setting the RS bit or by momentarily interrupting the power to the controller
(24 VDC supply voltage).
If an error message is reset with the RS bit, it is not actually reset until the RS bit is reset.
Invalid error messages may appear when the controller is switched off owing to the undefined operating state. This
must be taken into account when they are evaluated by the higher-level controller (e.g. a PLC) in order to avoid
false alarms.

8.19 Error messages

In addition to the error codes diagnosed in the event protocol, you can also access the PROFINET diagnosis func-
tion (extended device diagnosis). The error codes appear in the configuring tool in plain text because they are
stored in the device master file (GSDML).
The table below shows the meaning of the error codes. It includes a description of each error as well as the
required corrective action.
The block diagram in section 8.20 "Fault areas and causes" on page 54 helps you clear a particular error quickly
and efficiently.
Thirteen voltage levels for diagnosing errors appear at the RESISTRON® temperature controller’s actual value
output. The error messages are even more finely differentiated internally. The 3-digit error codes described below
can be displayed via the PROFINET interface or in the ROPEX visualization software ( section 8.12 "USB inter-
face for visualization software ROPEXvisual®" on page 47) to facilitate troubleshooting).

If the actual value output is evaluated in order to identify an error message – in the higher-level con-
! troller, for instance – the tolerance window must be adjusted to prevent incorrect interpretations.
Please note the tolerances of the actual value output ( section 10 "Technical data" on page 56).

Page 50 RES-5010 Version 4

Device functions

Part 1 of 3: Error messages (faults)

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

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

101 0.66 No current signal Fault area  Fault area 

102 1.33 No voltage signal Fault area  Fault area 

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

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

307
2.66
308 Temperature too high / low
- -
309 ( section 8.7.11)

310

No line frequency / line fre-

201
quency fluctuates

Line frequency too high /

202 3.33 Check power supply Check power supply
fluctuates

Line frequency too low /

203
fluctuates

Heatup time too long

304 4.00 Perform RESET Perform RESET
( section 8.7.12)

901 No line voltage / sync signal  Section 8.2  Section 8.2

913 Triac defective Replace device Replace device

914

915 4.66 Internal fault, device defective Replace device Replace device

916

917 Slide switch for alarm output

Check slide switch Check slide switch
918 incorrect

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 Device functions

Part 2 of 3: Error messages (warnings)

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

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

Current signal incorrect,

104 incorrect impulse transformer
specification

Voltage signal incorrect, Perform AUTOCAL ,

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

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

Page 52 RES-5010 Version 4

Device functions

Part 3 of 3: Error messages (warnings)

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

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

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

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

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

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

Current / voltage signals incor-

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

Perform AUTOCAL Perform AUTOCAL

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

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

Version 4 RES-5010 Page 53

 Device functions

8.20 Fault areas and causes

5 1 2 2 9

6 3
Temperature
4 controller

HARDWARE
9

8
UR
7
1
IR
8

The table below explains the possible fault causes.

Fault area Explanation Possible causes

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

pickoff point - Contact to heatsealing band is defective

Current transformer signal inter- - IR measurement cable from current transformer interrupted
rupted

- Wire break, triac in controller defective

Primary circuit interrupted - Primary winding of impulse transformer interrupted
 - Kb contactor open

Secondary circuit interrupted - Wire break

before UR pickoff point - Secondary winding of impulse transformer interrupted

 No UR signal - Measurement cable interrupted

- Heatsealing band partially bypassed by conducting part

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

- Wire break, heatsealing band break

 Parallel circuit interrupted
- Contact to heatsealing band is defective

- Heatsealing band incorrectly installed, no insulation at

 Total short-circuit heatsealing bar ends or insulation incorrectly installed
- Heatsealing band completely bypassed by conducting part

 UR signal incorrect - U2 outside of permissible range from 0.4…120 VAC

IR signal incorrect - I2 outside of permissible range from 30…500 A

 Wire incorrectly laid through cur- - Check number of turns (two or more turns required for
rent transformer currents < 30 A)

Page 54 RES-5010 Version 4

Device functions

Fault area Explanation Possible causes

- Hardware fault (replace controller)

Internal device fault / no line - Jumper for alarm relay not connected or incorrectly con-

voltage nected
- No line voltage

Version 4 RES-5010 Page 55

 Factory settings

9 Factory settings
The RESISTRON® temperature controller RES-5010 is configured at the factory as follows:

Rotary coding switch Heatsealing band alloy: Alloy A20

for ALARM OUTPUT DE-ENERGIZED
(AT ALARM)
Temperature range: 300 °C
heatsealing band alloy
CONFIGURATION
ENERGIZED

and Rotary coding switch: "0" position

AUX
PC CONFIGURATION 9

temperature range
3500ppm/K 8 300°C
780ppm/K (L) 5 500°C
1100ppm/K (A20) 4 500°C
0 780ppm/K (L) 1 300°C

789
12
1100ppm/K (A20) 0 300°C

34
TEMP. COEFFICIENT SWITCH POS. TEMP. RANGE
6 5

Slide switch Alarm relay energized at alarm

for ALARM OUTPUT DE-ENERGIZED
CONFIGURATION (AT ALARM)
alarm relay ENERGIZED
AUX

0
1
789

2 34
6

Automatic phase AUTOCOMP: Off

angle compensation
(AUTOCOMP)

Temperature Temperature diagnosis: Off

diagnosis

Heatup Heatup timeout: Off

timeout

10 Technical data
Operation of the temperature controller outside of these technical specifications results in loss of
! warranty and can cause defects.

Type of construction Housing for installation in an electrical cabinet

Snaps onto a standard top hat rail (TS35 rail, 35 mm) acc. to DIN EN 50022
Dimensions: 90 x 75 mm; depth: 135 mm (incl. terminals)

Page 56 RES-5010 Version 4

Technical data

Line voltage Connected between neutral conductor and one line conductor:
110 VAC -15%…300 VAC +10%
or
Connected between two line conductors:
until 01/2021: 110 VAC -15%…415 VAC +10%
as from 02/2021: 110 VAC -15%…480 VAC1 +10%

The voltage between the line conductor and ground must not be more
! than 300 VAC.

Power supply system Balanced TN or TT system

Installation category III

Operation in potential-free systems (e.g. an IT system) is only per-

! mitted after consultation with ROPEX.

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

Current consumption Imax = 5 A (duty cycle = 100%)

(primary current of Imax = 25 A (duty cycle = 20%, cycle duration 1 min)
impulse
transformer)

24 VDC supply 24 VDC, Imax = 200 mA

voltage Tolerance: ±10%
Terminals 5+7 SELV or PELV supplied from max. 300 VAC, Cat II

Measuring range Secondary voltage UR: 0.4…120 VAC

Secondary current IR: 30…500 A (with PEX-W4/-W5 current transformer)
 ROPEX Application Report

PROFINET interface "Conformance Class C", IO / RT and IRT acc. to IEC 61784-2
2 Ethernet switch ports RJ45
Wiring: IEC 61784-5-3
Data transfer rate: 100 Mbit/s
Data transport layer: Ethernet II, IEEE 802.3
Topology discovery: LLDP, SNMP V1, MIB2, physical device
Addressing: DCP or selectable with rotary coding switch
FSU (Fast Startup) support: Yes, but startup time approx. 2.5 s.

Heatsealing band The temperature range and temperature coefficient settings can also be specified
type and temperature in the ROPEX visualization software ( section 8.12 "USB interface for visualiza-
range tion software ROPEXvisual®" on page 47) in addition to using the rotary coding
switch or via the PROFINET interface (see below):
Temperature range: 200 °C, 300 °C, 400 °C, or 500 °C
Temperature coefficient: 400…4000 ppm/K (variable setting range)

Five different ranges can be set using the rotary coding switch or via the
PROFINET interface:
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)

Please take the necessary setting from the ROPEX application report

Version 4 RES-5010 Page 57

 Technical data

Analog output 0…10 VDC, Imax = 5 mA

(actual value) Equivalent to 0…300 °C or 0…500 °C
Terminals 17+18 Accuracy: ±1% plus 50 mV

Alarm relay Umax = 30 V (DC/AC), Imax = 1 A, changeover contact, potential-free

Terminals 12, 13, 14

Power loss Max. 20 W

Ambient conditions Max. altitude: 2000 m

Ambient temperature: +5…+45 °C
Max. relative humidity: 80% at temperatures up to +31 °C, decreasing linearly to
50% relative humidity at +45 °C

Degree of protection IP20

UL file E464680

Installation A minimum safety clearance of 20 mm all round

(e.g. from other devices and wiring) must be
allowed when installing the device.

The moving clip required for fastening must be

facing down for mounting on a horizontal top hat
rail.

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

Weight Approx. 0.5 kg (incl. connector plug-in parts)

Housing material Plastic, polycarbonate, UL-94-V0

Connecting cable Rigid or flexible; 0.2…2.5 mm² (AWG 24…12) plug-in connectors
Type / cross-sections
Plug-in connectors: 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. This is essential to ensure proper
electrical contact in the terminals.
1. Standard: 415 VAC, optional and on request: 480 VAC

Page 58 RES-5010 Version 4

Dimensions

11 Dimensions

135.0
113.0
75.0 90.0

12 Modifications

12.1 Modifications (MODs)

Owing to its universal design, the RESISTRON® temperature controller RES-5010 is suitable for a very wide range
of heatsealing applications.
One modification (MOD) is available for the RESISTRON® temperature controller RES-5010 for implementing
special applications.
The modifications must be ordered separately.

MOD 01
Booster for low secondary voltages (UR = 0.2…60 VAC). This modification is necessary, for example, for very
short or low-resistance heatsealing bands.

Version 4 RES-5010 Page 59

 How to order

13 How to order
Images exemplary

Controller RES-5010
Art. no. 7501000
Scope of supply: Controller includes connector plug-in parts
(without current transformer)

Modification MOD . . (optional, if required)

For example
01: MOD 01, art. no. 800001 (booster for low voltage)

Please indicate the article numbers of the controller and the required modifications
(optional) in all orders,
e.g. RES-5010 + MOD 01 (controller with booster for low voltage)
Order of art no. 7501000 + 800001

Current transformer PEX-W5

Art. no. 885107

Monitoring current transformer MSW-2

Art. no. 885212

Network 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.

Temperature meter ATR - .

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

Page 60 RES-5010 Version 4

How to order

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

Version 4 RES-5010 Page 61

 Index

14 Index
Numbers F
24VDC supply voltage 57 Factory settings 56
Fault 29
A Fault areas 54
AA bit 29 Fuse 12
Actual value 31
Actual value output 46 H
AC bit 26 Heatsealing band type 57
AG bit 29 Heatup timeout 39
Alarm output 49
Alarm relay 19, 58 I
Alloy 18, 21 Impulse transformer 12, 60
Altitude 58 Input data 26
AL bit 21, 29 Installation 9, 58
Ambient conditions 58 Installation procedure 9
Ambient temperature 58 Installation regulations 10
Application Report 10, 13
AUTOCAL 9, 21
Active 29 L
Blocked 26, 29 Line filter 5, 12, 13
Starting 26 Line frequency 57
AUTOCOMP 37 Line voltage 57
Automatic phase angle compensation 37
Automatic zero calibration 21, 26 M
Automatic zeroing 9 Maintenance 5, 56
AUTOTUNE 9 Master AUTOCAL (MA) 27
AUX interface 48 Measurement interruption 25, 30
Measurement pause 27
B Measuring impulse duration 36
Booster 16, 61 Measuring range 57
Booster connection 47 Modification MOD 59, 60
Burning in (heatsealing band) 19, 21 Monitoring current transformer 60
MP bit 27
MSW-2 60
C MU bit 30
Circuit-breaker 12
Control active 30
Current transformer 13, 60 N
Network filter 60
Network frequency 9
D
Data format 36
Data memory 48 O
Date 48 Output data 28
Degree of protection 58 Over-current protection 12
Device master file (GSDML) 24
Dimensions 59 P
Disposal 5 PEX-W4/-W5 5, 13
PEX-W5 60
E Phase angle compensation 37
Error code format 37 Power loss 58
Error diagnosis 9 Power supply 12
Error messages 50 Power supply system 57
External module/channel errors 36 PROFINET interface 57
External switching amplifier 16

Page 62 RES-5010 Version 4

Index

R Temperature regulation 8
RA bit 21, 30 TE bit 29
Relative humidity 58 Thermal impulse process 8
Replacement (heatsealing band) 20, 21 Time 48
Reset 27 Timestamp 48
ROPEXvisual 47 TO bit 29
RS bit 27 Transformer 4, 12, 60
Transportation 5
Type of construction 56
S
Set point 28
Standby mode 45 U
Start 26 UL file 58
Startup 17 Undervoltage detection 45
ST bit 21 USB interface 47
System diagnosis 47 Use 8
System monitoring 49
V
T View of the device 17
TCR 4, 19 Visualization software 47
TCR Calculator 35
Temperature achieved 29 W
Temperature coefficient 4, 19 WA bit 29
Temperature diagnosis 38, 39 Web server 41
Temperature meter 47, 60 Wiring 10, 12
Temperature OK 29 Wiring diagram 15, 16
Temperature range 18, 57

Version 4 RES-5010 Page 63