Thermosald Isx Manual Ver 6

THERMOSALD
ISX - IPX
A MODULAR SYSTEM
FOR
IMPULSE SEALING
NEW TECHNICAL FEATURES
THERMOREGULATOR CONFIGURABILITY
LOW VOLTAGE SUPPLY
PRECISION CALIBRATION PROBE
WORKING VOLTAGES FROM 230 TO 600 VOLTS
WORKING CURRENTS FROM 10 TO 500 AMPERE
IP65 PANEL OPTION
COPROCESSOR OPTION
PROFIBUS OPTION AND OTHER FIELD BUSES
ON-BOARD PLC OPTION WITH SEALING TIMES
MAXIMUM TEMPERATURE ALARM PROBE
CALIBRATING UP TO -30°C
RAM DATA CHECK IN RUN TIME (v4.4)
OTHER FEATURES
COMPLETELY AUTOMATIC CALIBRATION

ON-LINE THERMOREGULATOR SIZING
BEST DIAGNOSTICS FOR TROUBLESHOOTING
ALPHANUMERIC DISPLAY IN 6 LANGUAGES
COMPATIBILITY WITH ALL PREVIOUS MODELS
INSTALLATION AND USER MANUAL

(V6)
3E S.r.l. - Via del Maccabreccia 46 - 40012 LIPPO DI CALDERARA (BOLOGNA)
Tel. ++39 051 6466225 E-Mail: mail@3e3e3e.com
Fax ++39 051 6426252 Web: www.3e3e3e.com
1 INTRODUCTION ............................................................................................................... 4
2 SAFETY INSTRUCTIONS AND CERTIFICATIONS ......................................................... 5
2.1 SAFETY INSTRUCTIONS ......................................................................................................................5
2.2 COMPLIANCE WITH STANDARDS – CE MARKING ............................................................................5
3 DESCRIPTION .................................................................................................................. 6
3.1 INTRODUCTION ON THE MARKET ......................................................................................................6
3.2 DESCRIPTION OF THE PRODUCT AND ADVANTAGES.....................................................................6
3.3 OPERATING PRINCIPLE AND ADVANTAGES: ....................................................................................7
3.4 APPLICATIONS ......................................................................................................................................7
3.5 CONFIGURABILITY AND ADVANTAGES ..............................................................................................8
4 INSTALLATION............................................................................................................... 11
4.1 WARNINGS AND REQUIREMENTS FOR INSTALLATION .................................................................11
4.2 COMPONENT SELECTION AND TECHNICAL NOTES FOR INSTALLATION ...................................11
4.2.1 SECONDARY/PRIMARY THERMOREGULATOR ...........................................................................11
4.2.2 POWER TRANSFORMER AND SIZING ..........................................................................................11
4.2.3 SIZING THE PROTECTION DEVICES ............................................................................................12
4.2.4 ELECTROMECHANICAL SYSTEM ..................................................................................................12
4.2.5 MAINS FILTER .................................................................................................................................12
4.2.6 WIRING WITH BAND CONNECTION IN PARALLEL ......................................................................13
4.2.7 INSTALLATION.................................................................................................................................15
4.3 WIRING DIAGRAMS .............................................................................................................................16
4.3.1 DIGITAL SIGNAL CONNECTIONS ..................................................................................................16
4.3.2 CONTROL ON THE SECONDARY – POWER CONNECTIONS (THERMOSALD ISX MODEL) ....17
4.3.3 CONTROL ON THE PRIMARY – POWER CONNECTIONS (THERMOSALD IPX MODEL) -
PRELIMINARY ...............................................................................................................................................18
4.3.4 LOW COST WITH POTENTIOMETERS OR ANALOGUE OUTPUTS FROM PLC (THERMOSALD
ISX-IPX MODEL) ...........................................................................................................................................19
4.3.5 STANDARD WITH OPERATOR PANEL (THERMOSALD ISX-IPX MODEL) ..................................20
4.3.6 STANDARD WITH PROFIBUS / RS485 (THERMOSALD ISX-IPX MODEL + OPERATOR PANEL
OPTION) ........................................................................................................................................................21
4.3.7 STANDARD WITH CAN BUS (THERMOSALD ISX-IPX MODEL + OPERATOR PANEL OPTION)
22
4.3.8 STANDARD WITH PLC-ANALOGUE OPTION (THERMOSALD ISX-IPX MODEL + OPERATOR
PANEL OPTION) ...........................................................................................................................................23
4.3.9 PRECISION SENSOR ......................................................................................................................24
4.4 LIST OF EXCHANGE SIGNALS ...........................................................................................................25
5 COMMISSIONING ........................................................................................................... 28
5.1 COMMISSIONING WARNINGS ............................................................................................................28
5.2 THERMOSALD ISX-LC – IPX-LC (LOW COST secondary - primary).................................................28
5.3 THERMOSALD ISX – IPX (STANDARD+ MULTILANGUAGE PANEL) ..............................................29
5.4 THERMOSALD ISX – IPX (+ ANALOGUE OPTION)...........................................................................30
5.5 INSTRUCTIONS FOR USING THE MULTILANGUAGE PANEL..........................................................32
5.5.1 Homepage – (WARN 33 shows that there is no power on the input terminals) ................................32
5.5.2 Master Reset Page ...........................................................................................................................32
5.5.3 Calibration Page ................................................................................................................................33
5.5.4 PARAMETERS Pages (structure and notes of the parameters contained in the submenus) ...........33
6 MAINTENANCE .............................................................................................................. 36
THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21
Code: 3ES100_MDU_V6EN Page: 2 of: 60 Date: 06/09/2017
6.1 REPLACING THE BAND WITH THE MACHINE COLD (i.e. bars at ambient temperature – scheduled
maintenance) ......................................................................................................................................................36
6.2 REPLACING THE BAND WITH THE MACHINE HOT(i.e. bars at operating temperature - quick
intervention) ........................................................................................................................................................36
6.3 THERMOREGULATOR MAINTENANCE .............................................................................................36
6.4 GRIPPER JAWS MAINTENANCE ........................................................................................................36
7 TECHNICAL DATA ......................................................................................................... 37
7.1 TECHNICAL DATA FOR THE MODULATION-ON-THE-SECONDARY MODEL .................................37
7.2 TECHNICAL DATA FOR THE MODULATION ON THE PRIMARY MODEL ........................................38
8 ORDERING DATA........................................................................................................... 39
8.1 CODES FOR ORDERING .....................................................................................................................39
8.1.1 Models ...............................................................................................................................................39
8.1.2 Options applicable for all models ......................................................................................................40
8.1.3 Options applicable for models with bus (no _AB) .............................................................................40
8.1.4 Options applicable for models with ANYBUS (_AB) .........................................................................40
8.1.5 Options applicable for models with COPRO (_CO) ..........................................................................41
8.1.6 Accessories applicable for all models ...............................................................................................41
8.1.7 Apdater kits for previous models .......................................................................................................42
8.1.8 Stretching terminals ..........................................................................................................................42
8.1.9 Power transformer.............................................................................................................................42
8.1.10 Consumable ..................................................................................................................................42
8.1.11 Manuals for all models ..................................................................................................................43
8.1.12 Manuals for models with COPRO (_CO) ......................................................................................43
8.1.13 Manuals and exchange files for models with bus (no _AB) ..........................................................43
8.1.14 Manuals and exchange files for models with ANYBUS (_AB) ......................................................43
APPENDIX A – SEALING CYCLE ......................................................................................... 44
APPENDIX B - MACHINE DATA LIST ................................................................................... 45
APPENDIX B1 – PRIORITY MACHINE DATA managed directly on the MAIN MENU ....... 46
APPENDIX C - SETTING DATA LIST .................................................................................... 46
APPENDIX C1 – PRIORITY SETTING DATA managed directly on the MAIN MENU ........ 47
APPENDIX D – LIST OF ALARMS AND MESSAGES (CAUSES – REMEDIES).................. 48
APPENDIX E – MECHANICAL DIMENSIONS ....................................................................... 58
APPENDIX F – TABLE OF BANDS ....................................................................................... 59
APPENDIX G – COMMISSIONING SHEET ........................................................................... 60

1 INTRODUCTION
This manual is the only complete document concerning the product represented on the front
page. It contains safety instructions, a description of the device and some of its possible
applications, instructions for installing, commissioning, servicing and disposing of the product,
the codes and some examples for placing orders.
This manual is referred to in all the documents that accompany the product and must be
consulted before using the product described.
In particular, read the instructions related to safety, installation, commissioning, servicing and
disposal before using the product.
REVISION OF THE MANUAL:
Rev. Date SW Description

0 13/11/2010 V3.0
1 01/03/2011 V3.0
2 15/06/2011 V3.1
3 08/11/2011 V3.3
4 19/12/2011 V4.0
5 19/06/2012 V4.2
6 26/11/2012 V4.3
7 25/03/2013 V4.4
8 08/07/2013 V4.5
9 13/09/2013 V5.0
10 20/02/2014 V5.0
11 10/06/2014 V5.1
12 14/12/2014 V6.1
13 16/07/2015 V6.1
14 15/04/2016 V6.2
15 25/01/2017 V6.2 Revision of chapt. 8 and par 7.1
16 14/02/2017 V6.2
17 01/03/2017 V6.3
18 13/03/2017 V6.3
20 24/08/2017 V6.3
21 06/09/2017 V6.5

2 SAFETY INSTRUCTIONS AND CERTIFICATIONS
2.1 SAFETY INSTRUCTIONS
- A proper specific and technical knowledge is required to install, commission, service or use
the product. Consult this “USER MANUAL” and follow the instructions contained herein in
compliance with the SAFETY REGULATIONS.
- Improper use of the apparatus may result in dangerous conditions for the operator and
things and people nearby.
- Do not use the equipment in an explosive atmosphere or with explosive material.
- Do not use the equipment with flammable material without first taking the necessary safety
precautions.
- Install and use the thermoregulator only in industrial applications.
- Use bands or wires with an appropriate positive temperature coefficient
( >= 8 x 10E-4 , 800ppm/K).
- Do not change the temperature coefficient unless you have sufficient know how.
- Mechanically fix the thermoregulator to the plate using the fixing holes.
- Before connecting it to the mains, connect the ground protection conductor to the fixing bolt
which is identified by a yellow-green PE indicator on the heat sink. The protection conductor
must have the section >= the power conductor. We suggest to connect the ground protection
conductor directly to the zinc plated plate support, nearest to the ground screw bolt.
- Do not connect the power circuit of the thermoregulator when the machine’s mechanical
guards are open.
- Do not power the thermoregulator if the protective cover has been removed.
- After a MASTER RESET procedure has been performed, set the parameters correctly
before using the equipment.
2.2 COMPLIANCE WITH STANDARDS – CE MARKING
The device complies with the fundamental requirements set forth in the following European
Directives that apply to the product with reference to the harmonized standards below:
89/336/EEC EMC Directive and subsequent amendments 92/31/ECC and 93/68/EEC

CEI EN 61000-6-4 – Electromagnetic Compatibility (EMC) –
Emission for industrial environments
CEI EN 61000-6-3 – Electromagnetic Compatibility (EMC) –
Emission for residential environments
(con piattine <=3 x 0.2 in parallelo e filtro adeguato)
CEI EN 61000-6-2 – Electromagnetic Compatibility (EMC) – Part 6-2: Generic Standards -
Immunity for industrial environments
73/23/EEC /LOW VOLTAGE Directive and subsequent amendments 93/68/EEC
CEI EN 60204-1 – Safety of machinery – Electrical equipment of machines
Part 1: General requirements

3 DESCRIPTION
3.1 INTRODUCTION ON THE MARKET
THERMOSALD ISX – IPX is a modular line of products that can be configured and are
compatible with one another. This line has been designed to meet all demands in the
IMPULSE SEALING market. THERMOSALD ISX – IPX springs from the company’s long
experience in the impulse sealing field and maintains total compatibility with all previous
thermoregulators, namely THERMOSALD PWM, THERMOSALD SCR, THERMOSALD
UPSCR and THERMOSALD ISC.
3.2 DESCRIPTION OF THE PRODUCT AND ADVANTAGES
Like the previous impulse thermoregulators, THERMOSALD ISX – IPX can quickly heat a
sealing band or cutting/sealing wire to the set temperature without using additional probes.
This technology makes it possible to obtain very high working speeds for sealing
polyethylene, polypropylene, environment-friendly products and plastics in general.
The temperature is controlled directly on the sealing line and the temperature can be
maintained even at high speeds. It avoids temperature drift between the first sealing
operation and the next ones in production, it prevents the support bars from overheating, thus
avoiding any subsequent mechanical problems caused by expansion. A cooling air blow and
other precautions may further increase the speed and improve the sealing quality.
Below is a list of the most important functional-technical features of the new THERMOSALD
ISX – IPX product in the following order: first the new features of this new model, than the
features inherited from the previous ones.
- 24VNS insulated POWER SUPPLY: in the THERMOSALD ISX version with control on
the secondary, it allows the same thermoregulator to be used regardless of the mains
voltage.
- TEMPERATURE PROBE: it allows the band drift to be corrected over time
- POWER TRANSFORMER CONTROL ON THE SECONDARY OR PRIMARY: it allows
the User to choose the best solution to the problem he/she has to solve within a
voltage range of 230 to 600 Volts or current range of 150 to 400 Ampere.
- CONFIGURATION FREEDOM: it allows the user to choose the right model, from the
less expensive one which is COMPLETELY ANALOGUE, to the most expensive and
sophisticated model with COPROCESSOR and MODBUS RS485 FIELDBUS,
PROFIBUS, CAN and others.
- IP65 OPERATOR PANEL:
- ON-BOARD PLC: it allows the thermoregulator to be used with times and internal
logics for totally controlling small-sized semi-automatic sealing machines.
- COMPATIBILITY WITH ALL PREVIOUS THERMOREGULATORS: that allows spare

parts to be replaced on obsolete models

- Current sensor towards ground: to stop the machine in the case of an earth leak of the
band to ground and subsequent sealing malfunction.
- COMPLETELY AUTOMATIC CALIBRATION: just press the calibration button to
calibrate, without selectors or trimmers
- GUIDED SIZING OF THE POWER TRANSFORMER: the only sizing required is that of
the power transformer which can be done with the aid of a guided menu on the display
panel: the user enters the band data and the thermoregulator suggests the voltage,
current and power of the transformer to be used
- ON-LINE ANALYSIS OF THE RESISTANCE, VOLTAGE AND CURRENT VALUES
OF THE BAND: the equipment allows the theoretical, commissioning and run-time
values of the resistance, voltage, current and power to be displayed and compared so
as to help the operator troubleshoot any machine problems
- BEST DIAGNOSTICS FOR TROUBLESHOOTING: powerful diagnostics warns the
user of any problem that has occurred on the machine, from a wiring mistake during
installation to a failure problem during standard operation
- ALPHANUMERIC DISPLAY IN 6 LANGUAGES
3.3 OPERATING PRINCIPLE AND ADVANTAGES:
At all network cycles THERMOSALD ISX – IPX reads the voltage and current on the band,
calculates the resistance and then the temperature, which depends on the resistance, and
controls the current that heats the band in a closed loop; this current is generated by a power
transformer by means of phase control performed on the secondary of the power transformer
in the THERMOSALD ISX configuration and on the primary of the power transformer in the
THERMOSALD IPX configuration: selection can be made according to machine requirements
or company situations.
The new structure of the thermoregulator allows the user to operate without virtually having
voltage or current limits as the problem shifts completely on to the power transformer and the
system technical standards. For further information and details please refer to paragraph
CONFIGURATIONS AND ADVANTAGES below.
3.4 APPLICATIONS
On all packaging machines that require polyethylene, polypropylene, environment-friendly

and plastic films to be sealed or cut/sealed, vertical and horizontal filling machines, bundling
machines, shoppers, vacuum machines, etc.

3.5 CONFIGURABILITY AND ADVANTAGES
The thermoregulator that best suits machine requirements can be built with the same basic
dimensions, 120mm x 100mm.
MODEL FEATURES ADVANTAGES

- completely analogue Low cost
THERMOSALD ISX - LC - control on the secondary - It can be used with other
(LOW COST secondary) -one model for all mains mains from 230V to 600V
-for output currents up to without changing the
250A thermoregulator model
THERMOSALD IPX - LC - control on the primary - Very high currents for very
(LOW COST primary) -change of model in case of large bands
400V mains change
-for output currents up to
300A
PREHEAT POT.
SEALING POT.
CALIBRATION
BUTTON
ALARM RESET
BUTTON

120 x 100 H=130 -Digital temperature settings
-completely digital -Powerful Diagnostics
-precision sensor for zero -Sealing parameter change
point calibration -It allows the band drift to be
-temperature sensor on compensated
power module
THERMOSALD ISX - control on the secondary - It can be used with other
+ PANEL -one model for all mains mains from 230V to 600V
(standard secondary) - for output currents up to without changing the
280-400A thermoregulator model
THERMOSALD IPX - control on the primary - Possible implementations
+ PANEL -change of model in case of even with very high currents
(standard primary) 400V mains for very large bands
-for output currents up to
400A

120 x 100 H=170 -Digital temperature settings
-completely digital -Powerful Diagnostics
-precision sensor for zero -Sealing parameter change
point calibration -It allows the band drift to be
-temperature sensor on compensated
power module – Coprocessor Maximum flexibility
Option
-RS485 Modbus Option
-Profibus Option
-Can bus Option
-Analogue Option
-Sealing Times and PLC
Option
THERMOSALD ISX - control on the secondary - It can be used with other
+ PANEL -one model for all mains mains from 230V to 600V
+OPTIONS - for output currents up to without changing the
(secondary+options) 280-400A thermoregulator model
THERMOSALD IPX - control on the primary - Possible implementations
+ PANEL -change of model in case of even with very high currents
+IPX OPTIONS 400V mains for very large bands
(primary+options) -for output currents up to
400A

4 INSTALLATION
4.1 WARNINGS AND REQUIREMENTS FOR INSTALLATION
- BEFORE STARTING to INSTALL carefully read the SAFETY WARNINGS contained in this
manual.
- This apparatus must be installed in accordance with the requirements set forth in standard
CEI - EN60204
- This apparatus must be installed carefully following the instructions contained in this USER
MANUAL
- This apparatus must be installed by skilled and properly trained personnel
4.2 COMPONENT SELECTION AND TECHNICAL NOTES FOR INSTALLATION
(Please refer to the diagrams under paragraph 4.3)

Below are the calculations to define the voltage and current required for the best application;
select the suitable THERMOSALD ISX-IPX from the order table according to the values
calculated.
4.2.1 SECONDARY/PRIMARY THERMOREGULATOR
- The apparatus must be installed inside an electrical panel, protected against dust, water
and corrosive acids.
-The apparatus does not require special ventilation when used, but must be installed in a
properly ventilated area; when the machine reaches steady-state operation, check that the
heat sink of the thermoregulator does not exceed 60°C, if so, increase ventilation; a safety
temperature probe is installed in models ISX2 and IPX2.
4.2.2 POWER TRANSFORMER AND SIZING
- A power transformer must be connected to supply power to the sealing band as indicated in
the diagrams (ref. par. 4.3); in the case of a overlapped winding transformer, place a shield
between the primary and secondary to avoid mains leaks on the secondary
-The power transformer can be sized simply using the thermoregulator’s panel (diagnosis
menu – see description in the commissioning section) or as follows:
Calculate the band cross-section CROSS-SECTION[mm²] = WIDTH[mm] x
THICKNESS[mm]
Calculate rated heating current Inom [A]= 30[A/ mm²] x CROSS-SECTION[mm²]
Calculate useful resistance Ru[ohm]=Specific resistance[ohm x mm² / m] x Useful length [m] /
Cross-section [mm²]
Calculate the rated voltage and power
Vnom[V]= Ru[ohm] x Inom [A], Pnom= Vnom x Inom.
Follow the suggestions of the notes below:
NOTE1: maximum theoretical voltage VT and current IT of the transformer are calculated
according to the machine’s speed requirements: a coefficient x 1.5, x 2, i.e. VT=Vnom x
coefficient, IT=Inom x coefficient, can be applied.

NOTE2: the maximum theoretical power of the transformer is calculated without considering
the first full-wave heating impulses and according to a phase modulation mean factor, PT =
VT x ITx 0.7
NOTE3: the actual mean power of the transformer depends on the number of sealing
operations per minute, the ratio between the active state and sealing cycle period and the
thickness of the film to be sealed; due to overall dimension reasons and costs, the PT
theoretical power can be declassified introducing a SIF intermittent duty-type of the
transformer (which, according to experience, should be about 50%-40%).
4.2.3 SIZING THE PROTECTION DEVICES
Envisage a D CURVE protection thermal magnetic circuit breaker to disconnect the mains as
indicated in the diagrams (ref. par. 4.3).
Calculate the breaking current = theoretical heating current IT divided by secondary-primary
coils ratio Q.
Ithermal magnetic circuit breaker = IT / Q
NOTE1: the value of the protection device of the power transformer’s secondary must be the
same as or higher than the calculated theoretical current IT; this protection device trips on the
cables and band downstream of it. Considering that the thermoregulator is already fitted with
an electronic protection device on the cables’ and band’s current, the fitter should analyze the
possibility of not installing said protection device on the basis of the application.
NOTE2: please note that the suggested protection devices must be verified by the designer
according to the application.
4.2.4 ELECTROMECHANICAL SYSTEM
-The safety chain must be made like the one in the base drawing (ref. par. 4.3). the
emergency output contact must interrupt the power electromechanically; in particular, it must
open the contactor necessary for interrupting the power transformer’s power supply. this
contact must be suitable for the circulating currents; this interruption is crucial because if the
electronic switch inside the thermoregulator fails (very rare event), only the contactor can
prevent the bands from overheating and breaking.
- Install an emergency button as indicated in the diagrams (ref. Par. 4.3). It must only be
possible to reset this button manually and must be placed in a non-dangerous area that the
operator can access easily.
4.2.5 MAINS FILTER
-No cases of interference with equipment nearby have occurred with THERMOSALD ISX,
phase control on the secondary. The mains filter can be not mounted.
-A mains filter is recommended for THERMOSALD IPX, phase control on the primary.

4.2.6 WIRING WITH BAND CONNECTION IN PARALLEL
The previous picture shows a wiring with two bands in parallel (cables 1,2,7,8): for one single
band use only two cables (e.g. 1,8).
Thermoregulator
The themoregulator must be installed inside an electrical panel, screwed

on a iron plate zinc plated, in vertical position.
Amperometric transformer
The amperometric transformer must be mounted inside the electric panel near the
thermoregulator; cables must be twisted and must have a cross-section ≥ 0,5 mm.

Power terminals on the machine
Power terminals must have screws so an optimal connection is guaranteed

(do not use terminals with springs or similar) and must be positioned as near
as possible to the sealing bars.
In case more thermoregulators are used, each thermoregulator must have its
power terminals in an independent box: in this way the concatenation between cables of
different thermoregulators can be avoided.
Sealing bars
The sealing bars are connected to the power terminals by

means of power cables and, when possible, with the
reference cables. In the shown diagram the reference
cables start from power terminals on the machine and not from the sealing bar to make the
wiring easier: the compromise is acceptable for most applications.
The concatenation between cables connecting thermoregulator and sealing bars of different
themoregulators must be avoided.
The reference between the sealing band and PE is done by means of the thermoregulator;
do not connect the sealing band to PE directly.
Power cables
The power cables between the transformer and the thermoregulator, and between the
thermoregulator and the power terminals on the machine must be twisted.
The paths of the cables must be as much as possible linear, short and without turns which
can produce important inductive effects.
The thermoregulator passed immunity tests for heavy industrial environment; in any case it is
suggested to have the paths of the cables separated from cables of other devices producing
electrical noise (electrical welding devices, brushless electric drives, inverters).
It is mandatory to avoid proximity to power cables rolled up like coils because this causes a
very strong electromagnetic interaction that also the use of shields cannot reduce.
Cable cross-section must be:
• 10 mm² for bands with cross-section ≤ 2,0 mm² (es. 2 bands in parallel 4 x 0,25)
• 16 mm² for bands with cross-section > 2.0 mm² (es. 2 bands in parallel 6 x 0,3)
Reference cables
The reference cables must be shielded-twisted or, at least, twisted: in case shielded cable is
used, the shield must be connected only to thermoregulator side; for the best wiring the
reference cables should be connected directly on the terminal of one of the two bands; to
increase the strength of the plant and, according to our long time experience in the most of
cases, it is an optimal compromise to connect these cables to the power terminals on the
machine near to the sealing bands, like shown in the above diagram.

4.2.7 INSTALLATION
Electrically disconnect the electrical panel and make sure no voltage is being supplied to the
mains connection terminals.
Screw the thermoregulator on the bottom of the electrical panel.
Connect the ground wire (with the same cross-section as the power cables) to the
thermoregulator’s PE bolt.
Wire the power cables as described previously.
Wire the reference cables as described previously.
Perform the safety chain as described previously.

4.3 WIRING DIAGRAMS
4.3.1 DIGITAL SIGNAL CONNECTIONS
CN2 – POWER SUPPLY

2 1
THERMOSALD
ISX - IPX
FUSE
CN6 - REFERENCES EXTERNAL COMPONENTS
CN4 - PANEL
1 2 3 4 5 6
24VDC
SB
KM0
POWER ON
ALARM CN1 - POWER
BUTTON
CN3 - COMMANDS 1 2 3 4
1 2 3 4 5 6 7
IF
MUSHROOM
BUTTON
1 sq.mm
0VDC
PREHEAT CMD
SEALING CMD
RESET CMD
CALIBRATION CMD
KA0
24VDC
KA0
KA0 KM0
OUTPUT INPUT
THERMOSALD EMERGENCY
PLC ALARM CHAIN
0VDC
CONSTRUCTION NOTES:

4.3.2 CONTROL ON THE SECONDARY – POWER CONNECTIONS (THERMOSALD
ISX MODEL)
24VDC
400Vac 50/60Hz
0V
2 1
THERMOSALD
I> I> ISX
FUSE
KM0
CN6 - REFERENCES
CN4 - PANEL
1 2 3 4 5 6
BAND + REF.
SHIELDED
CABLE
CT – REF.
CT + REF.
SHIELDED
CABLE
BAND – REF.
Twisted
400V
Cable
0V
ALARM CN1 - POWER
1 2 3 4 5 6 7
VAC
0V
L1
L2
BAND -
BAND +
1
Power
Screened Twisted
4
Cable Cable
BAND +
BAND -
TECHNICAL NOTES:
In the case of the COPROCESSOR OPTION connector CN6, reference cable and the
amperometric transformer (CT) are doubled.
CONSTRUCTION NOTES:

4.3.3 CONTROL ON THE PRIMARY – POWER CONNECTIONS (THERMOSALD IPX
MODEL) - PRELIMINARY
230-480VAC
0VAC
24VDC
400Vac
0Vac
0V
50/60Hz
PH0 PH1
2 1
CN5 - SYNCHRONISM 2 1
I> I>
THERMOSALD
FUSE
IPX
CN6 - REFERENCES
CN4 - PANEL
MAINS 1 2 3 4 5 6
FILTER
SHIELDED
SHIELDED
CABLE
CABLE
TA + REF.
TA – REF.
BAND – REF.
BAND + REF.
twisted
ALARM CN1 - POWER
1 2 3 4 5 6 7
400V
terminal Nr. 3
0V
Grounded
Twisted
Cable
Screened
Cable
VAC
0V
1
4
Power
Twisted
Cable BAND +
BAND -
TECHNICAL NOTES:
In the case of the COPROCESSOR OPTION connector CN6, reference cable and the
amperometric transformer (CT) are doubled.
CONSTRUCTION NOTES:

4.3.4 LOW COST WITH POTENTIOMETERS OR ANALOGUE OUTPUTS FROM PLC
(THERMOSALD ISX-IPX MODEL)
AN-OUT
0V
3 2 1
CN8 – ANALOGUE OUTPUTS CN7 – ANALOGUE INPUTS

2 1
THERMOSALD
ISX - IPX
FUSE
CN6 - REFERENCES
CN4 - PANEL
1 2 3 4 5 6
ALARM CN1 - POWER
1 2 3 4 5 6 7
ANALOGUE OUTPUTS
OUTPUT INPUT
PLC

4.3.5 STANDARD WITH OPERATOR PANEL (THERMOSALD ISX-IPX MODEL)
THERMOSALD ISX - IPX

IMPULSE SEALING CONTROL
CN9 – TEMPERATURE PROBE

2 1
THERMOSALD CAL MODE RES

ISX - IPX FUSE
CN6 - REFERENCES
CN4 - PANEL
1 2 3 4 5 6
ALARM CN1 - POWER
1 2 3 4 5 6 7

4.3.6 STANDARD WITH PROFIBUS / RS485 (THERMOSALD ISX-IPX MODEL +
OPERATOR PANEL OPTION)
THERMOSALD ISX

2 1

ISX - IPX
FUSE
CN6 - REFERENCES
CN4 - PANEL
1 2 3 4 5 6
ALARM CN1 - POWER
1 2 3 4 5 6 7
PROFIBUS
RS485
OUTPUT INPUT
CN11 – CAN BUS CN10 – PROFIBUS / RS485
1 2 3 4 5

4.3.7 STANDARD WITH CAN BUS (THERMOSALD ISX-IPX MODEL + OPERATOR
PANEL OPTION)
THERMOSALD ISX

2 1

ISX - IPX FUSE
CN6 - REFERENCES
CN4 – PANEL
1 2 3 4 5 6
ALARM CN1 - POWER
1 2 3 4 5 6 7
CAN BUS
OUTPUT INPUT
CN11 – CAN BUS CN10 – PROFIBUS / RS485
1 2 3 4 5

4.3.8 STANDARD WITH PLC-ANALOGUE OPTION (THERMOSALD ISX-IPX MODEL
+ OPERATOR PANEL OPTION)
AN-OUT
0V
3 2 1
CN8 – ANALOGUE OUTPUTS CN7 – ANALOGUE INPUTS

2 1
THERMOSALD
ISX - IPX
FUSE
CN6 - REFERENCES
CN4 - PANEL
1 2 3 4 5 6
ALARM CN1 - POWER
1 2 3 4 5 6 7
1 2 3 4 5 6
6 7
7 8 9 CN12 – ANPLC
IN1- CLOSED
OUT3
OUT2
OUT4
IN2
IN3
24V
0V
OUT1-BAR
BAR
ANALOGUE
OUTPUT INPUT OUTPUT
PLC

4.3.9 PRECISION SENSOR
PROBE CONNECTOR (9 PIN MALE)
PIN1 0V - green wire (1 mA max)

PIN2 +5 Vcc - brown wire (1 mA max)
PIN3
PIN4
PIN5
PIN6
PIN7 CLOCK - yellow wire (1 mA max)
PIN8
PIN9 DATA - white wire (1 mA max)

4.4 LIST OF EXCHANGE SIGNALS
This list specifies the list of the connections and related PINS of
CN1 – POWER TERMINAL BLOCK (MODEL WITH CONTROL ON THE SECONDARY)

PIN1 ALTERNATING POWER SUPPLY
PIN2 ALTERNATING POWER SUPPLY
PIN3 BAND -
PIN4 BAND +
NOTE1: We recommend you twist the power cables
CN1 – POWER TERMINAL BLOCK (MODEL WITH CONTROL ON THE PRIMARY)

PIN1 ALTERNATING POWER SUPPLY INPUT (230VAC)
PIN2
PIN3 CONNECT TO 0V OF THE POWER SECONDARY TO CHECK GROUND
CURRENT
PIN4 PHASED POWER SUPPLY OUTPUT TO THE PRIMARY OF TRANSFORMER
NOTE1: We recommend you twist the power cables
NOTE2: Alternating supply of the control circuit with the same phase as that of the
power circuit
CN2 – CONTROL CIRCUIT POWER SUPPLY TERMINAL BLOCK

PIN 1 0 Vdc (max absorption: 0.5 A)
PIN 2 24 Vdc (max absorption: 0.5 A)
NOTE1: 0-24VDC is insulated from the internal power supply and ground
CN3 – COMMAND TERMINAL BLOCK

PIN1 0 V PLC COMMON (24 Vdc) (max absorption: 0.1 A)
PIN2 PREHEATING COMMAND FROM 24 Vdc PLC (0) (20 mA max)
PIN3 SEALING COMMAND FROM 24 Vdc PLC (0) (20 mA max)
PIN4 RESET COMMAND FROM 24 Vdc PLC (0) DC (20 mA max)
PIN5 CALIBRATION COMMAND FROM 24 Vdc PLC (0) DC (20 mA max)
PIN6 SEALING ALARM (N.C. CONTACT) (4 A max)
PIN7 SEALING ALARM (N.C. CONTACT) (4 A max)
CN4 – CONNECTOR FOR DISPLAY PANEL (15 POLES, FEMALE)

PIN1 +5 Vdc Shielded (0.25 sq.mm)
PIN2 0V Shielded (0.25 sq.mm)
PIN3 SPI-SDO Shielded (0.25 sq.mm)
PIN4 SPI-SCK Shielded (0.25 sq.mm)
PIN5 SPI-SDI Shielded (0.25 sq.mm)
PIN6
PIN7
PIN8
PIN9 SPI-SS Shielded (0.25 sq.mm)
PIN10 DO NOT USE Shielded (0.25 sq.mm)
PIN14
PIN15
NOTE1: The thermoregulator-panel connection cable must be shielded with pin-to-pin
connection. Max 15 m.
CN5 – PHASE INPUT TERMINAL BLOCK FOR SYNCHRONISM

PIN1 230-480 VAC MAIN NET SYNCRONISM (10ma max)
PIN2 0 VAC (10ma max)
CN6 – REFERENCE TERMINAL BLOCK

PIN1 REF- BAND REFERENCE (1 mA max)
PIN2 REF+ BAND REFERENCE (1 mA max)
PIN3 REF0 REFERENCE CABLE SHIELD (do not connect on
the machine side)
PIN4 CT- REFERENCE (500 mA max) twisted
cable
PIN5 CT+ REFERENCE (500 mA max) twisted
cable
PIN6 REF0 REFERENCE CABLE SHIELD (do not connect on
the machine side)
CN7 - POTENTIOMETER CONNECTOR (9 POLES, MALE)

PIN1 +4.5V PREHEAT POTENTIOMETER 10Kohm (1 mA max)
PIN2 REF+ PREHEAT POTENTIOMETER 10Kohm (1 mA max)
PIN3 0V PREHEAT POTENTIOMETER 10Kohm (1 mA max)
PIN4 jumper PIN3 and PIN4 (1 mA max)
PIN5
PIN6 +4.5V SEALING POTENTIOMETER 10Kohm (1 mA max)
PIN7 REF+ SEALING POTENTIOMETER 10Kohm (1 mA max)
PIN8 0V SEALING POTENTIOMETER 10Kohm (1 mA max)
PIN9 jumper PIN8 and PIN9 (1 mA max)
NOTE1: if piloted from analogue PLC output, use PIN2,PIN3,PIN7,PIN8 and leave PIN4-
PIN9 free.
NOTE2: REF-, REF+: we recommend you use a shielded twisted pair (e.g. TWINAX IBM
cable, our code 3esd0066)
CN8 – ANALOGUE OUTPUT TERMINAL BLOCK

PIN 1 0 Vdc ANALOGUE (5ma max)
PIN 2 0-5 Vdc ANALOGUE REFERENCE OUTPUT (5ma max)
PIN 3 ANALOGUE REFERENCE OUTPUT CABLE SHIELD

CN9 – TEMPERATURE PROBE CONNECTOR (9 POLES, FEMALE)
PIN1 0V (3ES109B1 green wire) (1 mA max)
PIN2 +5 Vdc (3ES109B1 brown wire) (1 mA max)
PIN3
PIN4
PIN5
PIN6
PIN7 OUT CLOCK (3ES109B1 yellow wire) (1 mA max)
PIN8
PIN9 DATA (3ES109B1 white wire) (1 mA max)
Connect 3ES109B1 screen to connector case.
CN10 - PROFIBUS / 485 SERIAL CONNECTOR (9 POLES, FEMALE)

PIN1
PIN2
PIN3 Profibus B- / Rs485 A+
PIN4 Profibus Enable Output
PIN5 0V floating Output
PIN6 +5V floating Output
PIN7
PIN8 Profibus A+ / Rs485 B-
PIN9
NOTE1: we recommend you use a shielded cable
CN11 – CAN BUS TERMINAL BLOCK

PIN1 CAN – V-
PIN2 CAN L
PIN3 0 V EXTERNAL (INSULATED)
PIN4 CAN H
PIN5 CAN – V+
CN12 – ANPLC TERMINAL BLOCK

PIN1 0 V COMMON
PIN2 IN0 Closed bar (10 mA max)
PIN3 IN1 (10 mA max)
PIN10 24 Vdc COMMON
PIN11 OUT0 CLOSED BAR (0-500 ma)
PIN12 OUT1 BLOW (0-500 ma)
PIN13 OUT2 (0-500 ma)
PIN14 OUT3 (0-500 ma)

5 COMMISSIONING
5.1 COMMISSIONING WARNINGS

-BEFORE STARTING COMMISSIONING carefully read the SAFETY WARNINGS and
INSTALLATION WARNINGS in the USER AND INSTALLATION MANUAL this chapter is an
integral part of or a copy of it.
-The system must have been sized as specified in the installation warnings and built in a
workmanlike fashion.
-The thermoregulator is provided in the MASTER RESET condition. After every
MASTER RESET the parameters return to the default status: if they were changed for
operation purposes, the working parameters are to be set; in this case 4 leds on the
equipment in the right are blinking.
-For any further information do not hesitate to contact 3E.
5.2 THERMOSALD ISX-LC – IPX-LC (LOW COST secondary - primary)
PREHEAT POT.
SEALING POT.
CALIBRATION
BUTTON
ALARM RESET
BUTTON
Step 1 – calibrate only after reading the commissioning warnings.
Step 2 – the machine must be at ambient temperature
Step 3 – the preheat and sealing commands must be deactivated
Step 4 – power the thermoregulator
Step 5 – in the event of an alarm, red ALARM LED on, follow the thermoregulator’s
suggestions and solve (the alarm number can be identified by counting the impulses of the
green balance LED for tens – e.g. 9 impulses = 90 - + the impulses of the red balance LED
for units – e.g. 10 impulses = 0).
Point 6 - calibrate: press the external CALIBRATION button and wait (the 2 LEDs on the
equipment blink during calibration)
Step 7 – at the end of calibration the machine is ready to work: set the preheat and sealing
temperature on the preheat and sealing potentiometers (30 degrees/turn)
NOTE 1: if calibration problems occur, perform a MASTER RESET and proceed from step 2
(to perform the MASTER RESET: keep the external RESET + CALIBRATION button pressed
for 6 seconds; the 4 LEDs on the equipment remain on for 3 seconds).
NOTE 2: for analog I/O go to paragraph 5.4 ANALOGUE OPTION

5.3 THERMOSALD ISX – IPX (STANDARD+ MULTILANGUAGE PANEL)
Step 1 – calibrate only after reading the commissioning warnings.

Step 2 – the machine must be at ambient temperature
Step 3 – the preheat and sealing commands must be deactivated
Step 4 – power the thermoregulator
Step 5 - in the event of an alarm, thermoregulator’s red ALARM LED on, follow the panel’s
suggestions and solve (the alarm number and the description in the language selected
among the 6 possible ones)
Point 6 - calibrate: keep the green CAL button on the multilanguage panel pressed for 3
seconds (the 2 LEDs on the equipment blink during calibration).
Step 7 – at the end of calibration the machine is ready to work; set the preheat and sealing
temperature in the TEMPERATURE submenu as specified in paragraph 5.5.4.
Step 8 – Press the RES button and follow the instructions to go back to the homepage
NOTE 1: for the next calibrations press the CAL+MODE+CAL buttons on the multilanguage
panel in sequence (see par. 5.5.3 Calibration Page)
NOTE 2: calibration can also be performed from outside, as described in paragraph 5.2 of the
LOW COST configuration.
NOTE 3: if calibration problems occurs, perform a MASTER RESET according to one of the
following procedures:
procedure 1 - Keep ARROW DOWN + ARROW UP on the multilanguage panel pressed for
6 seconds.
procedure 2 – Keep the external RESET + CALIBRATION buttons pressed at the same time
for 6 seconds
The 4 LEDs on the equipment remain on for 3 seconds during the MASTER RESET.

5.4 THERMOSALD ISX – IPX (+ ANALOGUE OPTION)
PREHEAT POT.
SEALING POT.
CALIBRATION
BUTTON
ALARM RESET
BUTTON
NOTE 1: set the CONFIGURATION MACHINE DATA=1 potentiometers+display to enable

the potentiometers.
NOTE 2: set the maximum preheat and sealing temperatures on the panel and decrease
them with the analogue inputs (with 2 potentiometers 10Kohm (30 degrees/turn) or with
analog plc output (13mV/degree – 13mv x 300°C = 3.9V, 4.2V alarm, range 0-5V)).
NOTE 3: please refer to paragraph 5.3 for the other functions.
NOTE 2: set the preheat and sealing temperatures with 2 potentiometers 10Kohm (30
degrees/turn) or with analogue plc outputs (13mV/degree – 13mv x 300°C = 3.9V, 4.2V
alarm, range 0-5V).

NOTE 4: the thermoregulators is equiped by an analog output 0-5V to output temperature in
case of standard functionment, to output alarm number in case of alarm.
Case of standard functionment without power (warn33):

Alarm relay output: closed (CN3/6-CN3/7)
Analog output: 0V
Case of standard functionment with power:

Alarm relay output: closed (CN3/6-CN3/7)
Analog output: temperature 10mv / degree (e.g. 1Volt = 100 degree)
Case of alarm (see alarm table, appendix D):

Alarm relay: open (CN3/6-CN3/7)
Analog output: 1.0 V alarm 78 – equipment not calibrated
1.5 V alarm 46 – no current signal
2.0 V alarm 48 – preheat potentiometer connections
2.0 V alarm 49 – seal potentiometer connections
2.5V alarm 69 – ground current
3.0V alarm 89 – break of 1 of 2 bands in parallel
3.5V alarm 93 – seal command without power
4.0V alarm 94 – reference cable interruption
4.5V alarm 97 – partial short circuit between the bands
4.5V alarm 76 – current too high-circuits in saturation
5.0V alarm non specific: see the blinking of leds green-red alarm.

5.5 INSTRUCTIONS FOR USING THE MULTILANGUAGE PANEL
NOTE: It is possible to go back to the homepage from any page by pressing the RES button
repeatedly.
NOTE: Press the MODE button to access the LEVEL 2 submenu pages and then the
ARROW DOWN ▼ and ARROW UP ▲ buttons.
NOTE: Any parameter displayed can be changed as follows:

Press the MODE button to access the change status: “? 080”
Press the ARROW UP button to change the data: “? 081”
Press the MODE button to exit the change status: “= 081”
NOTE: Confirmation is requested before saving a change to any parameter:

????CONFIRMATION????
YES=MODE NO=RES
Answer YES to confirm, NO to reset the previous data.
5.5.1 Homepage – (WARN 33 shows that there is no power on the input terminals)
To perform a MASTER RESET keep the arrow up and arrow

down button pressed for 6 seconds until figure 5.4.2 is
displayed
To CALIBRATE press the CAL + MODE + CAL button as
shown in figure 5.4.3.
For any PARAMETER access the submenu and search for
the parameter to be changed as indicated in the table under
paragraph 5.4.4.
5.5.2 Master Reset Page
Using the Master Reset procedure the

thermoregulator self-configures according to the
hardware installed. The parameters are initialized
as factory set: if a parameter has been changed, it
must be returned to the working condition.

5.5.3 Calibration Page
Press MODE to access the calibration page
Press the CAL button to start calibration
5.5.4 PARAMETERS Pages (structure and notes of the parameters contained in the
submenus)
Note: the parameters that are changed most frequently are indicated in red
TEMPERATURES (see appendix C1)

PREHEAT TEMP. We recommend you set it to 40° less than the sealing temp.
SEALING TEMP. Sealing temperature
INCREASE SEALING Increase of sealing temperature for band compensation
INCREASE NR Number of sealing for increasing temperature
RECOVERY TIME Time tor resetting initial temperature
BALANCE TEMPERATURE
THEORET. CALCULATIONS
BAND WIDTH Theoretical value to size the machine - not required for operation.
BAND THICKNESS Theoretical value to size the machine - not required for operation.
WIRE DIAMETER Theoretical value to size the machine - not required for operation.
BAND LENGTH Theoretical value to size the machine - not required for operation.
NO. IN PARALLEL Theoretical value to size the machine - not required for operation.
NO. IN SERIES Theoretical value to size the machine - not required for operation.
OHM for SQ.MM / M Theoretical value to size the machine - not required for operation.
AMPERE FOR SQ.MM Theoretical value to size the machine - not required for operation.
DUTY CYCLE Theoretical value to size the machine - not required for operation.
TECHNICAL ANALYSIS
IMAX Maximum RMS current (typical data of the thermoregulator model)
I2T Integral current per time unit
I Heating RMS current
THEORETICAL R Theoretical resistance of the band (resulting from theoretical calculations)
R0 Calibration Resistance
R RunTime Resistance
THEORETICAL I Theoretical full-wave RMS current of the band (from theoretical calculations)
I0 Calibration full-wave RMS current
I RunTime full-wave RMS current
THEORETICAL V Theoretical full-wave RMS voltage of the band (from theoretical calculations)
V0 Calibration full-wave RMS voltage
V RunTime full-wave voltage
THEORETICAL P Theoretical full-wave power of the band Vx I x0.7(from theoretical calculations)
P0 Calibration full-wave RMS power V x I x 0.7
P RunTime full-wave RMS power V x I x 0.7
RATING WORKING Rating working 0-100% (100% works not in protection – best running). The
data is updated any 10 seconds)
TEMP SENSOR ON ON= precision sensor enabled
ACT. 1 ON= precision sensor active
TEMP Precision Sensor Temperature
COMMANDS
PREHEAT CMD Manual control from the keyboard
SEALING CMD Manual control from the keyboard
BURN IN CMD Manual control from the keyboard
CMD IN CURRENT Manual control from the keyboard
EMERGENCY TEST
EMERGENCY TEST Press the MODE button to check the emergency chain
SAVE CALIBRATION DATA
SAVE CAL. DATA Press the MODE button to save the data of the last calibration
CONFIGURATION MODE
CONFIGURATION MODE 0=impulse sealing
TEMP.COEFF.(PPM)
TEMP.COEFF.(PPM) It is modified to adjust the thermoregulator to the material of the sealing band
CONFIGURATION 0=Impulse sealing (preset for extensions-do not change)
RESOLUTION System resolution in bit/degree
MAX SEAL. TEMPERATURE
MAX SEAL. TEMP. It is modified to change the band's working temperature limits
I2Tx1SEC
I2Tx1SEC Maximum rms current for 1 second
FIELD BUS
FIELD BUS Parameters for the RS485 Modbus or other Field Bus
SETTING DATA
LANGUAGE SELECT. Italian, English, French, German, Spanish, to be defined
DISPLAY DEGREES see Appendix C, Setting Data List
MAX SEAL. TEMP. see Appendix C, Setting Data List
G/SEC GRADIENT see Appendix C, Setting Data List
GROUND CURRENT see Appendix C, Setting Data List
WARN66 TIME see Appendix C, Setting Data List
SET PAGE1 TEMP. see Appendix C, Setting Data List
MACHINE DATA
RATED I see Appendix B, Machine Data List
RAMP see Appendix B, Machine Data List
PROP. G. KV see Appendix B, Machine Data List
INTEGRAL GAIN KI see Appendix B, Machine Data List
INT. THRESHOLD FI see Appendix B, Machine Data List
INT. THRESHOLD IN see Appendix B, Machine Data List
INT. THRESHOLD FS see Appendix B, Machine Data List
DERIVATIVE GAIN KD see Appendix B, Machine Data List
READ DELAY see Appendix B, Machine Data List
PARTIAL SHORT see Appendix B, Machine Data List
CIRCUIT FACTOR
ALARM DISABL1 see Appendix B, Machine Data List
ALARM DISABL2 see Appendix B, Machine Data List
CONFIGURATION DISPLAY see Appendix B, Machine Data List
PLC OPTION see Appendix B, Machine Data List
TEMP SENSOR ENABL. see Appendix B, Machine Data List
PASSWORD 1=P/2=T see Appendix B, Machine Data List
KEY PASSWORD see Appendix B, Machine Data List
INFORMATION
3E s.r.l. – BO – ITALY
CUSTOMER CARE mail@3e3e3e.com
THERMOREG.MODEL THERMOSALD ISX / IPX
THERMOREG.VERSION Thermoregulator Software Release
DISPLAY VERSION Panel Software Release

6 MAINTENANCE
6.1 REPLACING THE BAND WITH THE MACHINE COLD (i.e. bars at ambient
temperature – scheduled maintenance)
1 – Power off, remove the preheat and sealing commands, let the gripper jaws cool down.
2 – Mount the new bands.
3 – Power on.
4 – Calibrate in order to compensate for any minor mechanical differences of the band (in
most cases ambient temperature does not need to be changed in the setting data).
5 – THE MACHINE is ready to work.
6.2 REPLACING THE BAND WITH THE MACHINE HOT(i.e. bars at operating
temperature - quick intervention)
1 – Power off, remove the preheat and sealing commands, let the gripper jaws cool down so
the operator can work comfortably.
2 – Mount the new bands.
3 – Power on.
4 – If there are no great mechanical differences in the bands THE MACHINE is ready to
work.
6.3 THERMOREGULATOR MAINTENANCE
To be scheduled according to the work environment, in any case with routine maintenance
intervals should be no longer than 180 days.
1 – Make sure the connection terminals are properly screwed.
2 – Periodically check correct operation of the output safety alarm contact (press the mode
button as requested at start-up to check the alarm circuit: the emergency output relay must
open and the power circuit must remain disconnected).
6.4 GRIPPER JAWS MAINTENANCE
To be scheduled according to the work environment at periodic intervals.

1 – Make sure the feedback reference terminals and power terminals are properly screwed.
2 – Make sure the band’s terminals are highly conductive and do not show any oxidation or
bad contacts: if so, service them accurately.
3 – Check the band’s supports in insulating material and Teflon.

7 TECHNICAL DATA
7.1 TECHNICAL DATA FOR THE MODULATION-ON-THE-SECONDARY MODEL
CONTROL POWER SUPPLY (CN2) 24VDC +/- 20% (max absorption: 0.2 A)
POWER SUPPLY SECONDARY POWER TRANSFORMER
STANDARD MODEL 10V-70V (seal bands 20cm-200cm)
LOW VOLTAGE MODEL 5V-10V (seal bands < 20cm)
HIGH VOLTAGE MODEL 70V-140V (seal bands > 70cm)
60A MODEL For a total band cross-section <= 2sq.mm
90A MODEL For a total band cross-section > 2sq.mm
SHORT CIRCUIT CURRENT 180A(mod.60)
400A(mod.90)
I2T STANDARD - I2T MAX CURRENT 150-180A(mod.60) 260-300A(mod.90)
MAINS FREQUENCY 50 – 60 Hz automatic switchover
DIGITAL COMMANDS 24 VDC (max absorption: 20 ma)
SEALING ALARM CONTACT 250 V 1 A (2A MAX)
STANDARD RESOLUTION 0.3 degree
REPETITIVENESS  +/- 1°C
PRECISION Depend of the thermic drift of sealing band
PREHEATING TEMPERATURE Can be set on the display panel 0-300°C
SEALING TEMPERATURE Can be set on the display pannel 0-300°C
SEALING AND COOLING-DOWN TIME External by PLC
WORKING ENVIRONMENT TEMPER. -20°C + 40°C
WORKING ENVIRONMENT HUMIDITY <50%
THERMOREGULATOR PROTECTION IP20
RATING
PANNEL PROTECTION RATING IP44 (IP65 WITH OPTION)
POWER UNIT WEIGHT kg 1.6

7.2 TECHNICAL DATA FOR THE MODULATION ON THE PRIMARY MODEL
CONTROL POWER SUPPLY (CN2) 24VDC +/- 20% (max absorption: 0.2 A)
POWER SUPPLY 230-480VAC
STANDARD MODEL 10V-80V (seal bands 20cm-200cm)
LOW VOLTAGE MODEL 5V-10V (seal bands < 20cm)
HIGH VOLTAGE MODEL 70V-140V (seal bands > 70cm)
SHORT CIRCUIT CURRENT 400 Ampere
I2T STANDARD - I2T MAX CURRENT 300-400A
MAINS FREQUENCY 50 – 60 Hz automatic switchover
DIGITAL COMMANDS 24 VDC (max absorption: 20 ma)
SEALING ALARM CONTACT 250 V 1 A (2A MAX)
REPETITIVENESS  +/- 1°C
PREHEATING TEMPERATURE Can be set on the display pannel 0-300°C
SEALING TEMPERATURE Can be set on the display pannel 0-300°C
SEALING AND COOLING-DOWN TIME External by PLC
WORKING ENVIRONMENT TEMPERAT. -20°C + 40°C
WORKING ENVIRONMENT HUMIDITY <50%
THERMOREGULATOR PROTECTION IP20
RATING
PANNEL PROTECTION RATING IP44 (IP65 WITH OPTION)
POWER UNIT WEIGHT kg 1.6

8 ORDERING DATA
8.1 CODES FOR ORDERING
8.1.1 Models
ITEM CODE DESCRIPTION Details
3ES103S6V6 THERMOSALD ISX 60A 3L Standard Impulse thermoregulator
SECONDARY 60 Ampere (3 levels)
3ES104S6V6_AB THERMOSALD ISX 60A 4L Impulse thermoregulator
ANYBUS SECONDARY 60 Ampere (4 levels)
For ANYBUS option
3ES104S6V6_CO THERMOSALD ISX 60A 4L Impulse thermoregulator with COPRO, redundant, top
COPRO reliability, NO ATEX CERTIFICATION.
For ANYBUS option
For ANYBUS option
3ES105S6V6_CO_AB THERMOSALD ISX 60A 5L Impulse thermoregulator with COPRO, redundant, top
COPRO ANYBUS reliability, NO ATEX CERTIFICATION.
For ANYBUS option
For ANYBUS option
3ES105S9V6_CO_AB THERMOSALD ISX 90A 5L Impulse thermoregulator with COPRO, redundant, top
COPRO ANYBUS reliability, NO ATEX CERTIFICATION.
For ANYBUS option

8.1.2 Options applicable for all models
3ES100Z=HV THERMOSALD ISX - See technical data
OPTION HIGH VOLTAGE (+0 Levels)
3ES100Z=LV THERMOSALD ISX - See technical data
OPTION LOW VOLTAGE (+0 Levels)
3ES100Z=AN THERMOSALD ISX - 2 Input + 1 output analog
OPTION ANALOG (+1 Level)
Cannot be used with 3ES100Z=CO_T180C900 and
3ES100Z=CO_T130C900 options
3ES100Z=AN_10V THERMOSALD ISX - 2 Input 10V + 1 output analog
OPTION ANALOG 10V (+1 Level)
3ES100Z=ANPLC THERMOSALD ISX - 2 Input + 1 output analog + PLC
OPTION ANALOG + PLC (+1 Level)
3ES100Z=PLC THERMOSALD ISX - PLC+ Times
OPTION PLC (+1 Level)
3ES100Z=T500 THERMOSALD ISX - Extended temperature range up to 500°C
OPTION T=500°C
3ES100Z=PRB THERMOSALD ISX – Internal option for external temperature sensor.
INTERNAL OPTION For models with COPRO see par. 8.1.5.
PRECISION SENSOR
8.1.3 Options applicable for models with bus (no _AB)

3ES100Z=RS485_V5 THERMOSALD ISX - OPTION RS485 MODBUS fieldbus
RS485 (+1 Level)
3ES100Z= THERMOSALD ISX - OPTION PROFIBUS fieldbus
PROFIBUS_V5 PROFIBUS (+1 Level)
8.1.4 Options applicable for models with ANYBUS (_AB)

3ES100Z= THERMOSALD ISX - OPTION Profinet 2 port by standard module
AB_PROFINET_V5 PROFINET ANYBUS AB6221 Anybus AB6221 fieldbus
(+0 Levels)
3ES100Z= THERMOSALD ISX - OPTION Ethernet IP 2 port by standard
AB_ETH_IP_V5 ETHERNET/IP ANYBUS AB6224 module Anybus AB6224 fieldbus
(+0 Levels)

8.1.5 Options applicable for models with COPRO (_CO)
3ES100Z=CO_PRB THERMOSALD ISX – Internal option for external temperature
INTERNAL OPTION sensors.
PRECISION SENSORS (+0 Levels)
3ES100Z=CO_PRB_T180C900 THERMOSALD ISX - Internal option for external temperature
INTERNAL OPTION sensors and fixed parameters: Maximum
PRECISION SENSORS + temperature=180°C, Temperature
TMAX=180 COEFF.T=900 coefficient=900 PPM
(+0 Levels)
3ES100Z=CO_PRB_T130C900 THERMOSALD ISX - Internal option for external temperature
INTERNAL OPTION sensors and fixed parameters: Maximum
PRECISION SENSORS + temperature=130°C, Temperature
TMAX=130 COEFF.T=900 coefficient=900 PPM
(+0 Levels)
8.1.6 Accessories applicable for all models

3ES109B1 THERMOSALD ISX – Temperature precision sensor
PRECISION SENSOR
3ES108V6 THERMOSALD ISX – Digital multilanguage panel for
MULTILANGUAGE PANEL thermosald
3ES108Z=IP65 THERMOSALD ISX - OPTION
PANEL IP65
3ES080A001/1 THERMOSALD PANEL CABLE Panel-thermoregulator connection
MT. 1 cable mt.1
MT. 3 cable mt.3
MT. 5 cable mt.5
MT. 10 cable mt.10
MT. 20 cable mt.20
3ES080A002 THERMOSALD TRANSFORMER Current amperometric transformer
AMPEROMETRIC Note: models with copro (_CO)
need two amperometric
transformers

8.1.7 Apdater kits for previous models
To replace a previous model 24V power is required. For SCR, PWM, UPSCR replacement an
electrical adapter kit and a mechanical frame are available, like described in the following
table.
3EPE0043A1 THERMOSALD ISX – ADAPTER
KIT FOR UPSCR
3EPE0044A1 THERMOSALD ISX
ANALOG/ISX-LC – ADAPTER
KIT FOR PWM/SCR
3EPE0045A1 THERMOSALD ISX WITHOUT
ANALOG – ADAPTER KIT FOR
PWM/SCR
3ES108Z=ISX-UPSCR THERMOSALD ISX - OPTION
PANEL FRAME ISX ON UPSCR
PROFILE
8.1.8 Stretching terminals

3EPM0104A_SP15_15_K45 STRETCHING TERMINAL FOR BAR 15
BLOCK 15 BAND 6 KG 4.5
3EPM0104Z=T15 OPTION T SHAPE BLOCK 15
8.1.9 Power transformer

For the sizing of the power transformer suitable for your application contact 3E technical support.
8.1.10 Consumable
Bands, belts and sealing wires with different profiles, in meters, specifically designed, copper-plated, teflon-
coated are available.
Teflon and insulators with different profiles, in meters, specifically designed are available too.

8.1.11 Manuals for all models
3ES100_MDU_V6_IT Thermosald ISX Installation and user manual V6 ITALIAN
3ES100_MDU_V6_EN Thermosald ISX Installation and user manual V6 ENGLISH
8.1.12 Manuals for models with COPRO (_CO)

3ES100_COPRO_V6_IT Thermosald ISX Installation and user manual COPRO V6 ITALIAN
3ES100_COPRO_V6_EN Thermosald ISX Installation and user manual COPRO V6 ENGLISH
8.1.13 Manuals and exchange files for models with bus (no _AB)
Thermosald ISX Installation and user manual
3ES100_RS485_V5_IT
RS485 V5 ITALIAN
3ES100_RS485_V5_EN
RS485 V5 ENGLISH
3ES100_PROFI_V5_IT
PROFIBUS V5 ITALIAN
3ES100_PROFI_V5_EN
PROFIBUS V5 ENGLISH
3ES100_BUS_GSD_V5 Thermosald ISX BUS Profibus GSD V5
8.1.14 Manuals and exchange files for models with ANYBUS (_AB)
3ES100_PRONET_V5_IT
PROFINET V5 ITALIAN
3ES100_PRONET_V5_EN
PROFINET V5 ENGLISH
3ES100_BUS_GSDML_V5 Thermosald ISX BUS PROFINET GSDML V5
3ES100_ETHER_IP_V5_IT
Ethernet/IP V5 ITALIAN
3ES100_ETHER_IP_V5_EN
Ethernet/IP V5 ENGLISH
3ES100_BUS_EDS_V5 Thermosald ISX BUS Ethernet/IP EDS V5

APPENDIX A – SEALING CYCLE
NOTE - The sealing cycle suggested is given by way of example only and is not to be
considered as a binding usage diagram. Experience shows that the timing must be
changed according to the specific application, i.e. of the materials, dimensions, times,
etc. For further information please contact our technical department.
WELDING CYCLE
PRE-HEATING SIGNAL
(IN THERMOSALD)
SEALING SIGNAL
(IN THERMOSALD)
closed
FILM GRIPPER JAWS
open
closed
BAND SEALERS
open
COOLING
FILM FEED
STARTING 1° STEADY CYCLE 2° STEADY CYCLE N° STEADY CYCLE

APPENDIX B - MACHINE DATA LIST
NOTE – The machine data must be changed only by skilled and qualified personnel after contacting our
technical department
TO ACCESS: press the MODE button on the MACHINE DATA submenu

TO EXIT: press the RES button
RATED I = 60 / 90 / 120 (AMPERE)

Cannot be changed, it shows the rated current of the model used
HEATING RAMP = (U.M. = degrees/100ms, default = 40)
Temperature increase rate following a preheat or sealing command [U.M. : degrees/100 ms].
Increasing this parameter means decreasing the time required to bring the band to the proper temperature,
subsequently increasing speed, reducing stability, decreasing band life.
PROPORTIONAL GAIN KV = (U.M., default = 100)
Proportional loop gain. Increasing this parameter means increasing the loop reply speed and therefore making
the system more ready.
Increasing it too much may result in system instability and subsequently in temperature oscillation.
INTEGRAL GAIN KI = (U.M., default = 40)
Integral loop gain. Increasing this parameter means increasing temperature accuracy and the speed for
achieving the temperature desired. Increase this parameter to increase system stability.
Increasing it too much may result in a temperature overflow subsquent to a preheat or sealing command.
INTEGRAL THRESHOLD LIMIT FI= (default = 60%) (soft.v4.4)
It limits the maximum value of the integrative component in heat zone: increasing this value it increases the hot
overshoot (contact our technical office)
INTEGRAL THRESHOLD LIMIT IN= (default = 0%) (soft.v4.4)
It limits the maximum value of the integrative component in cold zone: increasing this value it increases the
speed of heating (contact our technical office)
INTEGRAL THRESHOLD LIMIT FS= (default = 80%) (soft.v4.4)
It limits the maximum value of the integrative component in production: increasing this value it increases the
temperature of the bar in production (contact our technical office)
DERIVATIVE GAIN KD = (U.M., default = 30)
Derivative loop gain. Increasing this parameter means increasing the loop reply speed and therefore making the
system more ready to changes.
Increasing it too much may result in system instability and subsequently in temperature oscillation.
READ DELAY = (default = 1200usec.) (soft.v4.4)
It can modify the time of reading the analog converter; modifying this parameter help to improve the
performance of the thermoregulator when an undersize power transformer is used(contact our technical office)
PARTIAL SHORT CIRCUIT FACTOR = (U.M. , default = 1.2)
It allows an instantaneous current threshold to be established, due to a partial short circuit, above which the
thermoregulator goes in alarm condition F097.
ALARM DISABLING1 = 0 (U.M.)
It allows any alarm to be disabled. To be used carefully. In certain cases it may allow the production cycle to
restart. Alarm disabling must be considered temporary and actions must be taken immediately to remove its
causes.
ALARM DISABLING2 = 0 (U.M.)
It allows any alarm to be disabled. To be used carefully. In certain cases it may allow the production cycle to
restart. Alarm disabling must be considered provisional and actions must be taken immediately to remove its
causes.
DISPLAY CONFIGURATION = 2
1=operation with potentiometers: the temperature set on the display can be limited by the analogue input.
2=operation with display only or FIELD BUS
PLC OPTION (default = OFF)
It is put to ON when the PLC card is plugged in, for managing sealing gripper jaw movement and sealing times
TEMPERATURE SENSOR ENABLING (ON/OFF)
It is automatically acquired during the MASTER RESET
PASSWORD ENABLING = 0
1=partial password; 2=total password
KEY PASSWORD (default = 0000)
Another password can be entered to block the data
APPENDIX B1 – PRIORITY MACHINE DATA managed directly on the MAIN MENU

(see par.5.5.4 parameters pages)
BALANCE TEMPERATURE (default = 30)

It can be changed according to the ambient temperature during calibration; with the PRECISION SENSOR
option this parameter is changed automatically at the end of a calibration procedure
TEMPERATURE COEFFICIENT (ppm – parts per million, default =1210)
It allows the thermoregulator to be adjusted to the type of band used. See safety standards in this manual. The
value required is to be set again after a MASTER RESET.
CONFIGURATION MODE (default =0)
0=standard impulse sealing: control loop much reliable, fits perfectly to the machine conditions.
MAX Sealing TEMPERATURE (default = 250)
It can be changed according to the maximum temperature allowed. The value required is to be set again after a
MASTER RESET.
I2T for 1 SECOND (default = 200 Ampere)
It can be decreased according to the protection rating desired on the machine
APPENDIX C - SETTING DATA LIST
NOTE – The machine data must be changed only by skilled and qualified personnel after contacting our
technical department.
TO ACCESS: press the MODE button on the SETTING DATA submenu

TO EXIT: press the RES button
LANGUAGE SELECTION (default=ITALIANO)

It is possible to select up to 6 languages: ITALIAN, ENGLISH, FRENCH, GERMAN, SPANISH, TO BE
DEFINED
DISPLAY DEGREES (default=CENTIGRADE)
It allows the user to select whether the temperature is to be displayed in Celsius or Fahrenheit degrees.
MAXIMUM SEALING TIME (SECONDS, default = 0.0)
Sealing time check. It allows the maximum time of the sealing command to be set. If the sealing command lasts
longer than this value, the thermoregulator goes in alarm condition F085.
For applications with a sealing command that is always high, this parameter must be set to 0.
TEMPERATURE GRADIENT FOR BALANCE (DEGREES/10 SECONDS, default = 4)
It shows the maximum temperature cooling down speed expressed in degrees/10 seconds above which the
balance is not enabled and warning 38 appears. Increasing this parameter may result in a loss of accuracy.
BAND TO GROUND (default = 20%); It can be changed
Soft V3.0(ground current=1000ma),Soft V3.1(1000ma),Soft V3.2(1000ma),Soft V3.3(20%)
WARN TIME = (SECONDS, default = 3)
In the case of warning the thermoregulator signals the failure without going to an alarm condition and stopping.
The message is displayed for the seconds specified by this parameter. If this parameter = 0 the message is not
displayed, if this parameter is maximum value = 10 the message is dispayed till to reset.

SET PAGE1 TEMP. (default = 0)
It allows the sealing temperature to be changed directly on the main page using the ARROW UP and ARROW
DOWN buttons
SET TEMP.END SEAL (default = 0)
1=Latch the temperature at the end of sealing
APPENDIX C1 – PRIORITY SETTING DATA managed directly on the MAIN MENU

(see par.5.5.4 parameters pages)
PREHEAT TEMPERATURE (default = 100)

It allows to set pre-heat temperature (we suggest to set 40-50 degree less than the seal temperature).
SEAL TEMPERATURE (default = 150)
It allows to set the seal temperature
INCREASE SEALING (default = 0)
It allow to compensate the decrease of temperature caused by the large of the bag to seal, less than 80% of the
active zone (zone in the middle of the sealing band not copper plated)
INCREASE SEALING is the total increase of the sealing temperature in degree.
TECHNICAL NOTE: the increase of temperature happens:
1)In impulse sealing on the down trigger of the seal command
2)In continuos sealing on the up trigger of the pre-heat command when seal command is on.
INCREASE NR (default = 0)
It’s the number of sealing necessary to obtain the total increase of sealing temperature INCREASE SEALING
RECOVERY TIME (default = 0)
It’s the time in seconds necessary to reset the initial condition of sealing temperature.

APPENDIX D – LIST OF ALARMS AND MESSAGES (CAUSES – REMEDIES)
NOTE – To reset any alarm raise the RESET command from the interface and press the
RESET / MODE button
NOTE – When in the alarm condition the RED LED lights up; the alarm number can be
deducted from the green and red LED blinking:
ALARM NO.=NO. OF GREEN LED IMPULSES x 10 + NO. OF RED LED IMPULSES
NOTE – When in the warning condition the YELLOW LED lights up; the warning number can
be deducted from the green and red LED blinking:
WARNING NO.=NO. OF GREEN LED IMPULSES x 10 + NO. OF RED LED IMPULSES
NOTE – Any warning is displayed for the second set in the setting data WARN TIME
ALARM DESCRIPTION REMEDY
FAULT A thermoregulator completely OFF plus Check the power supply; power
display completely OFF supply unit faulty; contact the
supplier
FAULT C THERMOREGULATOR WITH LED Check the display connection
OPERATING AND DISPLAY ON cable
SHOWING “3E SRL + THERMOSALD"
F001 EEPROM WRITING INTERRUPTED Switch the equipment OFF and
then ON; then contact the
supplier
F002 EEPROM WRITING WITH PREVIOUS Switch the equipment OFF and
OPERATION IN PROGRESS then ON; then contact the
supplier
F003 EEPROM WRITING WITH FAULTY Switch the equipment OFF and
EEPROM then ON; then contact the
supplier
F004 INDEX CORRUPTED SOFWARE Switch the equipment OFF and
STRUCTURE READ-WRITE EEPROM then ON; then contact the
supplier
F006 PANEL FLASH EEPROM WRING Switch the equipment OFF and
then ON; then contact the
supplier
F007 A/D CONVERTER –CONVERTER Switch the equipment OFF and
WRITING ERROR then ON; then contact the
supplier
F008 INTERNAL I2C-X TRANSMISSION Switch the equipment OFF and
then ON
F009 DO NOT USE
F010 A/D CONVERTER –CHANNEL Switch the equipment OFF and
SELECTION ERROR then ON; then contact the
supplier
F011 COPROCESSOR SELECTOR ON WITH Coprocessor card problems;
COPRO CARD NOT ACTIVE OR SEL. perform a Master Reset and
COPRO OFF WITH COPRO CARD ACT. contact the supplier
F012 INTERNAL BUS CARD TRANSMISSION Switch the equipment OFF and
then ON; then check the
parameters
F013 INTERNAL COPROCESSOR CARD Switch the equipment OFF and
TRANSMISSION then ON; then check the
parameters
F014 FIELD BUS STOPPED Switch the equipment OFF and
then ON
F018 RS485 SLAVE – UNKNOWN COMMAND Check RS485 master is sending
allowed commands
F019 RS485 MASTER - CHECKSUM ERROR Check checksum selection on the
Master and Slave
F020 RS485 SLAVE - CHECKSUM ERROR Check checksum selection on the
Master and Slave
F021 RS485 SLAVE - OE OVERRUN ERROR Data have arrived before finishing
reading the previous ones
F022 RS485 SLAVE - FERR FRAME ERROR Stop bit has not arrived
F023 RS485 MASTER – NO REPLY FROM After a call of the Master the
SLAVE called Slave does not reply
F024 RS485 SLAVE – TOO MUCH DATA The Master has asked the Slave
REQUESTED BY THE MASTER OR for too much data or issued an
INCORRECT DATA ADDRESS address that is not enabled
F025 RS485 SLAVE - BUFFER FULL The buffer of the slave is full
because too much data have
been requested or arrived or
transmissions are too frequent
F026 RS485 MASTER - OE OVERRUN ERROR Data have arrived before finishing
reading the previous ones
F027 RS485 MASTER - FERR FRAME ERROR Stop bit has not arrived
F028 RS485 MASTER – TOO MUCH DATA The Slave has asked the Master
REQUESTED BY THE SLAVE OR for too much data or issued an
INCORRECT ADDRESS address that is not enabled
F029 RS485 MASTER - BUFFER FULL The buffer of the Master is full
because too much data have
arrived
F032 WARNING WAITING POWER DURING Switch power on
CALIBRATING
F033 WARNING: no VOLTAGE IN THE POWER Check the CN1/L1,L2 power
TRANSFORMER OR BAND NOT supply, the power transformer
CONNECTED circuit, check connection of the
power cables on the band.
F034 DO NOT USE
F035 WARNING – CALIBRATION REQUEST It is used in the RS485 remote
STATUS control
F036 WARNING – STATUS OF CALIBRATION It is used in the RS485 remote
IN PROGRESS control to check the end of
calibration
F037 EXTERNAL TEMPERATURE PROBE NOT Check temperature probe
ACTIVE connection or TEMPERATURE
PROBE Enabling machine data
F038 WARNING – Waiting for machine to cool To perform a calibration
down upon calibration request procedure it is necessary to wait
until the sealing bar reaches a
stable temperature.
F039 WARNING – Sealing temperature not No power for the first sealing:
reached increase sealing time.
F041 DEFAULT HARDWARE DATA RAM Switch the equipment OFF and
CONTROL REAL TIME CORRUPTED then ON; then contact the
supplier
F046 NO CURRENT SIGNAL Check CT connection, band
WITH VERY LOW CURRENT ALSO CT power cable and CN1/L1-L2
SIGNAL REVERSED connections.
F047 CT SIGNAL REVERSED Reverse CT connection
Attention at connection CN6/4-5
And not CN6/5-6
F048 PREHEAT POTENTIOMETER NOT Check preheat potentiometer
CONNECTED OR CABLES connections
INTERRUPTED
F049 SEALING POTENTIOMETER NOT Check sealing potentiometer
CONNECTED OR CABLES connections
INTERRUPTED
F051 WIPER-IGROSS Switch the equipment OFF and
then ON; if the problem persists,
contact the supplier
F052 WIPER-VGROSS Switch the equipment OFF and
F053 WIPER-IFINE Switch the equipment OFF and
F054 WIPER-VFINE Switch the equipment OFF and
F059 PERIOD OF MAIN NET OUT OF RANGE Switch the equipment OFF and
(from V4.2) then ON
F060 RESET WITH CALIBRATION IN Repeat calibration
PROGRESS
F061 IGROSS BALANCE NOT SUCCESSFUL Repeat calibration
F062 VGROSS BALANCE NOT SUCCESSFUL Verify if Band +/- Ref are
connected together, if power
transformer is well connected.
Verify if voltage power transf. is
right; Repeat calibration
F063 IFINE BALANCE NOT SUCCESSFUL Repeat calibration
F064 VFINE BALANCE NOT SUCCESSFUL Repeat calibration
F065 SUPERFINE BALANCE NOT Repeat calibration
SUCCESSFUL
F066 WARNING: SYNCHRONISM DUE TO Verify connection power
MAINS FREQUENCY OSCILLATION - transformer and Main Frequency
MAINS SYNCHRONISM INTERFERENCE
F067 TEMPERATURE>TEMPERATURE Verify connection sealing bands,
MAXIMUM FOR 800MS increase value of max temperat.
F068 TEMPERATURE>TEMPERATURE Verify connection sealing bands,
MAXIMUM+10 DEGREE FOR 200MS increase value of max temperat.
F069 GROUND CURRENT Check the band on the machine
or the band connection, probably
grounded.
NOTE: the thermoregulator is
grounded via a ground screw, the
band wires must therefore be
disconnected before checking
using an electrical instrument.
F071 HARDWARE FAULT – ANALOGUE +/–15V Reset the equipment; if the
BREAKAGE problem persists, contact the
supplier
F072 HARDWARE FAULT – ANALOGUE +/-5V Reset the equipment; if the
supplier
F073 HARDWARE FAULT – REFERENCE +5V Reset the equipment; if the
supplier
F074 INTERNAL TEMPERATURE PROBE – Switch the equipment OFF; if the
HEAT SINK TEMPERATURE TOO HIGH problem persists, contact the
supplier
F075 WARNING INTERRUPT FIRE BLOCK Verify connection power
transformer and Main Frequency
F076 IREAD TOO HIGH Check if there is a short circuit on
the bands
F077 MANUAL CMD FROM THE PANEL NOT Remove the preheat and sealing
ACTIVE DUE TO PREHEAT OR SEALING before giving the command
FROM OUTSIDE
F078 EQUIPMENT NOT CALIBRATED Perform the automatic calibration
procedure without giving the
preheat or sealing command
F079 EMERGENCY CIRCUIT FAULT Check the power contactor, check
the emergency chain
F080 BACK_FIRE TIMER CONTROL Reset the equipment; if the
problem persists, contact the
supplier
F081 HARDWARE FAULT – CHECKSUM Inconsistent data have been
ALARM READING EEPROM found on eeprom, proceed
carefully
Press RESET/MODE, check
MACHINE DATA, SETTING
DATA and TEMPERATURES set.
Contact the supplier
F082 phase displacement between syncronism Make sure the two power
(CN5) and power supply (CN1) – only supplies are in phase (pay
primary model attention to the phase-
phase/phase-neutral phase
displacement)
F083 REFERENCE CABLES REVERSED WITH Check the reversed reference
RESPECT TO THE POWER CABLES cables:
Supply -15V internal CN1/3 corresponds to CN6/1
CN1/4 corresponds to CN6/2
F085 SEALING TIME HIGHER THAN THE Check the sealing time on the
SEALING TIME MACHINE DATA SEALING TIME MACHINE
DATA; the sealing time control
can be excluded by setting the
SEALING TIME MACHINE DATA
=0
F089 BREAK OF A BAND IN CASE OF BANDS Check the bands
CONNECTED IN PARALLEL
F090 SHORT CIRCUIT BETWEEN THE BANDS Check the bands, check power
OR BETWEEN THE BANDS AND cabling between the
GROUND thermoregulator and bands
And not CN6/5-6
F091 I2T CURRENT TOO HIGH ALARM Check the band on the machine
or the band connections. Power
delivered too high
And not CN6/5-6
Verify input CN6/4-CN6/5
=10 ohm
F092 POWER COMPONENT FAULTY Reset the equipment; if the
manufacturer
F093 NO CURRENT ON THE BAND USED FOR Check the power transformer,
SEALING check for any interruption of the
band, check for any interruption
of the power cables
F094 REFERENCE CABLE INTERRUPTION Check the reference cables
(CN6/1 - CN6/2)
F095 NO MAINS SYNCHRONISM – NOT Internal hardware problem.
ACTIVE IN THE ISX-IPX MODELS Contact the manufacturer
F096 V-I TOO HIGH - NOT ACTIVE IN THE ISX- Saturation on the voltage circuit;
IPX MODELS check the system, probably a
band broke if it is connected in
parallel
F097 PARTIAL SHORT CIRCUIT BETWEEN Check the bands on the machine,
THE BANDS Probably they are not insulated
correctly.
If the band is fine and the
problem persists, let the machine
cool down and calibrate.
Pay attention to the machine’s
behaviour in the subsequent
working phases. To remove the
problem the PARTIAL SHORT
CIRCUIT FACTOR MACHINE
DATA can also be raised.
F098 POWER COMPONENT FAULTY PHASE 1 Reset the equipment; if the
manufacturer
F099 ALARM UNKNOWN Contact the manufacturer
F100 NOT USED
F101 COPROCESSOR EEPROM WRITING Switch the equipment OFF and
INTERRUPTED then ON; then contact the
supplier
WITH PREVIOUS OPERATION IN then ON; then contact the
PROGRESS supplier
WITH FAULTY EEPROM then ON; then contact the
supplier
F104 COPROCESSOR INDEX CORRUPTED Switch the equipment OFF and
SOFWARE STRUCTURE READ-WRITE then ON; then contact the
EEPROM supplier
F107 COPROCESSOR A/D CONVERTER – Switch the equipment OFF and
CONVERTER WRITING ERROR then ON; then contact the
supplier
F108 INTERNAL I2C-X TRANSMISSION Switch the equipment OFF and
COPROCESSOR then ON
F109 DO NOT USE
F110 COPROCESSOR A/D CONVERTER – Switch the equipment OFF and
CHANNEL SELECTION ERROR then ON; then contact the
supplier
F132 WARNING WAITING POWER DURING Switch power on
CALIBRATING COPRO
F133 COPROCESSOR WARNING - NO Check the CN1/L1,L2 power
VOLTAGE IN THE POWER supply, check the power
TRANSFORMER OR BAND NOT transformer circuit, check the
CONNECTED power cable connection on the
band
F134 DO NOT USE
F137 COPROCESSOR EXTERNAL Check the temperature probe
TEMPERATURE PROBE NOT ACTIVE connection or COPROCESSOR
TEMPERATURE PROBE
Enabling machine data
F138 WARNING – WAITING FOR MACHINE TO To perform a calibration
COOL DOWN procedure it is necessary to wait
until the sealing bar reaches a
stable temperature.
F143 BASIC TEMPERATURE <> Verify CT cables of coprocessor
COPROCESSOR TEMPERATURE and processor; possible
connection defective
F144 BASIC TEMPERATURE > Proceed carefully; calibrate,
COPROCESSOR TEMPERATURE+16 check the processor open CT
(FOR 5 IMPULSE) cables; contact the supplier
F145 COPROCESSOR TEMPERATURE > Proceed carefully; calibrate,
BASIC TEMPERATURE+16 check the coprocessor open CT
(FOR 5 IMPULSE) cables; contact the supplier
F146 COPROCESSOR - NO CURRENT SIGNAL Check the CT connections and
band power cable connections
F147 COPROCESSOR CT SIGNAL REVERSED Reverse the CT connection
F151 COPROCESSOR WIPER-IGROSS Switch the equipment OFF and
F152 COPROCESSOR WIPER-VGROSS Switch the equipment OFF and
F153 COPROCESSOR WIPER-IFINE Switch the equipment OFF and
F154 COPROCESSOR WIPER-VFINE Switch the equipment OFF and
F0159 PERIOD OF MAIN NET OUT OF RANGE Switch the equipment OFF and
(from V4.2) then ON
F160 COPROCESSOR RESET WITH Repeat calibration
CALIBRATION IN PROGRESS
F161 COPROCESSOR IGROSS BALANCE NOT Repeat calibration
SUCCESSFUL
F162 COPROCESSOR VGROSS BALANCE Repeat calibration
NOT SUCCESSFUL
F163 COPROCESSOR IFINE BALANCE NOT Repeat calibration
SUCCESSFUL
F164 COPROCESSOR VFINE BALANCE NOT Repeat calibration
SUCCESSFUL
F165 COPROCESSOR SUPERFINE BALANCE Repeat calibration
NOT SUCCESSFUL
F166 COPROCESSOR WARNING: Verify connection power
SYNCHRONISM DUE TO MAINS transformer and Main Frequency
FREQUENCY OSCILLATION -
MAINS SYNCHRONISM INTERFERENCE
F167 COPROCESSOR TEMPERATURE > Proceed carefully; check the
MAXIMUM TEMPERATURE preheat and sealing
(FOR 600MS) temperatures; check the
maximum temperature
parameter; contact the supplier,
check the coprocessor open CT
cables
F168 COPROCESSOR TEMPERATURE > Proceed carefully; check the
BASIC TEMPERATURE+10 preheat and sealing
(FOR 100MS) temperatures; check the
maximum temperature
parameter; contact the supplier,
check the coprocessor open CT
cables
F169 COPROCESSOR GROUND CURRENT Check the band on the machine
or the band connection, probably
grounded.
NOTE: the thermoregulator is
grounded via a ground screw, the
band wires must therefore be
disconnected before checking
using an electrical instrument.
F170 COPROCESSOR READ=0 WITH PHASE Current passes without any
OPEN AND HIGH CURRENT reading enable signal; contact the
supplier
F171 COPROCESSOR HARDWARE FAULT – Reset the equipment; if the
ANALOGUE +/–15V BREAKAGE problem persists, contact the
supplier
ANALOGUE +/-5V BREAKAGE problem persists, contact the
supplier
REFERENCE +5V BREAKAGE problem persists, contact the
supplier
F174 COPROCESSOR INTERNAL Switch the equipment OFF; if the
TEMPERATURE PROBE – HEAT SINK problem persists, contact the
TEMPERATURE TOO HIGH supplier
F175 COPROCESSOR WARNING INTERRUPT Verify connection power
FIRE BLOCK transformer and Main Frequency
F176 COPROCESSOR IREAD TOO HIGH Check if there is a short circuit on
the bands
F178 COPROCESSOR NOT CALIBRATED Calibrate
F179 COPROCESSOR DON’T RECEIVE FROM Reset the equipment; if the
MASTER INTERNAL TRASMISSION DATA problem persists, contact the
BUS supplier
F180 COPROCESSOR READ ENABLE NOT Reset the equipment; if the
RECEIVED problem persists, contact the
supplier
F181 COPROCESSOR HARDWARE FAULT – Proceed carefully; Press
CHECKSUM ALARM READING EEPROM RESET/MODE, check MACHINE
DATA, SETTING DATA and
TEMPERATURES set. Contact
the supplier
F182 COPROCESSOR AND BASIC Make sure both temperature
TEMPERATURE ENABLING probes are connected or
INCONSISTENT disconnected; then perform a
NOT ACTIVE FROM SOFTW >=V5.1 MASTER RESET to acquire
F183 COPROCESSOR REFERENCE CABLES Check the reversed reference
REVERSED WITH RESPECT TO THE cables:
POWER CABLES CN1/3 corresponds to CN6/1
CN1/4 corresponds to CN6/2
F184 COPROCESSOR SEALING COMMAND Switch the equipment OFF and
INCONSISTENT WITH BASIC (INTERNAL then ON; if the problem persists,
CONTROL) contact the supplier
(Coprocessor does not receive
CO_SALD_IN_ACT from base)
F0185 SEALING TIME HIGHER THAN THE Check the sealing time on the
SEALING TIME MACHINE DATA SEALING TIME MACHINE
NOT ACTIVE FROM SOFTW >=V5.1 DATA; the sealing time control
can be excluded by setting the
SEALING TIME MACHINE DATA
=0
F190 COPROCESSOR SHORT CIRCUIT Check the bands, check the
BETWEEN THE BANDS OR BETWEEN power cabling between the
THE BANDS AND GROUND thermoregulator and bands
F191 COPROCESSOR I2T CURRENT TOO Check the band on the machine
HIGH ALARM or the band connections. Power
delivered too high
F193 COPROCESSOR NO CURRENT ON THE Check the power transformer,
BAND USED FOR SEALING check for any interruption of the
band, check for any interruption
of the power cables
F194 COPROCESSOR REFERENCE CABLE Check for any interruptions in the
INTERRUPTION reference cables (CN6/1 - CN6/2)
F195 COPROCESSOR NO MAINS Internal hardware problem.
SYNCHRONISM, NOT ACTIVE IN THE Contact the manufacturer
ISX-IPX MODEL
F196 COPROCESSOR V-I TOO HIGH, NOT Saturation on the voltage circuit;
ACTIVE IN THE ISX-IPX MODEL check the system, probably a
band broke if it is connected in
parallel
F197 COPROCESSOR PARTIAL SHORT Check the bands on the machine,
CIRCUIT BETWEEN THE BANDS Probably they are not insulated
correctly.
If the band is fine and the
problem persists, let the machine
cool down and calibrate.
Pay attention to the machine’s
behaviour in the subsequent
working phases. To remove the
problem the PARTIAL SHORT
CIRCUIT FACTOR MACHINE
DATA can also be raised.
F199 COPROCESSOR ALARM UNKNOWN Contact the supplier
.

APPENDIX E – MECHANICAL DIMENSIONS
DIGITAL PANEL: 96x48 – REAR DIMENSIONS: 90.5x44.5

DEPTH = 73mm + Connector 52mm
45 [mm] DRILLING TEMPLATE
92 mm
NOTE: with IP65 protection, code 3ES108Z=IP65, do drilling template 94mm x 47mm,
Maximum external size 102mm x 54mm
THERMOREGULATOR DIMENSIONS
100 x 120 (VIEW FROM TOP)
HEIGHT = 135mm (3 Levels model) / 155mm (4 Levels model) / 175mm (5 Levels
model)
DRILLING TEMPLATE
3 HOLES Dia.=4.5 mm
120 [mm] 95 [mm]
82[mm]
20 [mm]
100 [mm]

APPENDIX F – TABLE OF BANDS
TABLE OF THE CHAMFERED BANDS IN SPECIAL ALLOY

(Band extension 50PPM, 0.05mm/metre per degree – 5mm/metre per 100 degrees)
Band Width Band Thickness Specific Resistance R0

(mm) (mm) /m
1.5 0.3 1.67
2 0.25 1.59
3 0.1 2.95
3 0.15 1.95
3 0.2 1.50
3 0.25 1.27
4 0.15 1.40
4 0.25 0.96
5 0.2 0.8
5 0.25 0.69
6 0.1 1.6
6 0.2 0.72
8 0.1 1.2
8 0.2 0.51
TABLE OF THE T-SHAPE BANDS IN SPECIAL ALLOY

(mm) (mm) /m
2.8 0.3 0.9
4 0.3 0.6
TABLE OF THE BEADED ELEMENT BANDS IN SPECIAL ALLOY

(mm) (mm) /m
4 0.15 1.4
4 0.25 0.9
6 0.15 0.99
6 0.25 0.6
TABLE OF THE CONCAVE BANDS IN SPECIAL ALLOY

(mm) (mm) /m
2.8 0.3 0.9

APPENDIX G – COMMISSIONING SHEET
SEALING BANDS WIDTH X THICKNESS

SEALING BANDS TOTAL LENGTH
USEFULL LENGTH (TOTAL - COPPER
TRANSFORMER POWER [VA]
TRANSFORMER PRIMARY VOLTAGE [V]
TRANSFORMER SECONDARY VOLT [V]
THERMOSALD ISX / IPX MODEL
ORDERED OPTIONS
PREHEAT TEMPERATURE [°C]

SEALING TEMPERATURE [°C]
SEALING TIME [Sec.]
TABLE OF THE DATA CHANGED DURING COMMISSIONING
DEFAULT NEW
(MACHINE DATA, SETTING DATA, COMMISSIONING DATA)
VALUE VALUE


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THERMOSALD

NEW TECHNICAL FEATURES

COMPLETELY AUTOMATIC CALIBRATION

COMPATIBILITY WITH ALL PREVIOUS MODELS

INSTALLATION AND USER MANUAL

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

REVISION OF THE MANUAL:

Rev. Date SW Description

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

2.1 SAFETY INSTRUCTIONS

2.2 COMPLIANCE WITH STANDARDS – CE MARKING

89/336/EEC EMC Directive and subsequent amendments 92/31/ECC and 93/68/EEC

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

3.1 INTRODUCTION ON THE MARKET

3.2 DESCRIPTION OF THE PRODUCT AND ADVANTAGES

- COMPATIBILITY WITH ALL PREVIOUS THERMOREGULATORS: that allows spare

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

3.3 OPERATING PRINCIPLE AND ADVANTAGES:

On all packaging machines that require polyethylene, polypropylene, environment-friendly

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

MODEL FEATURES ADVANTAGES

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

4.1 WARNINGS AND REQUIREMENTS FOR INSTALLATION

4.2 COMPONENT SELECTION AND TECHNICAL NOTES FOR INSTALLATION

(Please refer to the diagrams under paragraph 4.3)

4.2.1 SECONDARY/PRIMARY THERMOREGULATOR

4.2.2 POWER TRANSFORMER AND SIZING

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

4.2.3 SIZING THE PROTECTION DEVICES

4.2.4 ELECTROMECHANICAL SYSTEM

4.2.5 MAINS FILTER

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

The themoregulator must be installed inside an electrical panel, screwed

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

Power terminals must have screws so an optimal connection is guaranteed

The sealing bars are connected to the power terminals by

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

4.3.1 DIGITAL SIGNAL CONNECTIONS

CN2 – POWER SUPPLY

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

ALARM CN1 - POWER

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

ALARM CN1 - POWER

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

CN2 – POWER SUPPLY

ALARM CN1 - POWER

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

THERMOSALD ISX - IPX

CN9 – TEMPERATURE PROBE

CN2 – POWER SUPPLY

THERMOSALD CAL MODE RES

ALARM CN1 - POWER

THERMOSALD ISX – IPX – INSTALLATION AND USER MANUAL Rev.: 21

CN9 – TEMPERATURE PROBE

CN2 – POWER SUPPLY

THERMOSALD CAL MODE RES

ALARM CN1 - POWER