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Summary of Contents for Toss PIREG 545
- Page 1 PIREG ® -545 Operator’s Guide Phone: (610) 759-8883 E-Mail: info@tossheatseal.com 539 South Main Street Nazareth, PA 18064 Fax: (610) 759-1766 Web: www.tossheatseal.com PIREG 545 cUL Operators Guide 2021...
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Page 2: Table Of Contents
5.2.2. Single-point temperature coefficient correction: ..................15 5.2.3. 8-Point Temperature-coefficient correction: ................... 16 5.3. O ................................16 STATE 5.4. O ................................16 N STATE 5.5. T ..............................16 IME CONTROL 5.5.1. Preheating: .............................. 16 5.5.2. Start delay: .............................. 17 PIREG 545 cUL Operators Guide 2021... - Page 3 Configuration Menu 204 – Variable Tc Setting ....................35 Configuration Menu 204 a-d – Variable Tc Settings ..................35 Configuration Menu 205 – Temperature Range ....................35 Configuration Menu 206 – Maximum Temp. Setting ..................35 PIREG 545 cUL Operators Guide 2021...
- Page 4 Advance Config. Menu 314 – Auto Accept Value Changes ................41 Advance Config. Menu 315 – Total Life Cycles ....................42 Advance Config. Menu 316 – PIREG 545 Software Version ................42 Advance Config. Menu 317 – Reset Input Function ................... 42 Advance Config.
- Page 5 8.4. S ............................53 EALING TRANSFORMER 8.5. E DTM3000 ........................53 XTERNAL THERMOMETER 8.6. O ..............................54 RDERING CODES 8.7. S ............................... 54 PARE PARTS 9. APPLICATION NOTE ............................54 9.1. A ........................... 54 PPLICATION INSTRUCTIONS PIREG 545 cUL Operators Guide 2021...
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Page 6: General, Safety And Warning Instructions
® -545 resistance temperature controller may only be used for the heating and tem- perature control of TOSS approved heat seal bands as via isolating transformers in accordance with the regulations, notes and warnings contained in this description. Non-observance of the instructions or incorrect use of the equipment can result in impairment of the safety or overheating of the heat seal band, the electrical wiring or the transformer. -
Page 7: Impulse Transformer
For best results, the transformer's performance and the secondary voltage must be properly designed for the given heat seal band (refer to the TOSS Application Report). The rate of the heat-up time is determined by the secondary voltage being supplied. The proper selection of the secondary voltage for a target tem- perature increase of 300°C should only allow for a heat-up period of ... -
Page 8: Ce Conformity & Cul Listing
Electromagnetic compatibility (EMC) – Part 6-3: Generic standards - Emission standard for residential, commercial and light-industrial environments A suitable line filter is required for packaging machinery so that the machinery is compliant with the electromagnetic compatibility directive. 2011/65/EU, RoHS directive PIREG 545 cUL Operators Guide 2021... -
Page 9: Maintenance
-545 resistance temperature-controller is a temperature controller with a built-in time control, which is used to control the temperature of genuine TOSS Alloy 20 heat seal band material, or suitable heat seal bands, for impulse heat sealing of polymeric films, laminate films, and non-woven materials, and for controlling some basic functions of heat sealing machines. -
Page 10: Installation Overview
2.1. Installation Overview 2.2. PIREG ® -545 rear electrical pin-out PIREG 545 cUL Operators Guide 2021... -
Page 11: Wiring Diagram For The Pireg ® -545
® 2.3. Wiring diagram for the PIREG -545 ® 2.4. Wiring diagram for the PIREG -545 WITH external solid-state relay (Booster) PIREG 545 cUL Operators Guide 2021... -
Page 12: Installation And Commissioning
(or multiple times). Refer to the TOSS application report. 3.3. Configuring the settings Prior to initial operation, the correct temperature coefficient must be set for the genuine TOSS Alloy 20 heat seal band material, or the suitable heat seal band material being used. Setting too high a temperature coefficient may lead to overheating of the heat seal band. -
Page 13: External Solid State Relay (Booster)
3.9. Burning in the genuine TOSS Alloy 20 heat seal band With the sealing tool held open, the genuine TOSS Alloy 20 heat seal band should be "burnt in" in such a way that the "Start" signal is applied and a target temperature is slowly increased from zero. The final burn- in temperature should be at least 50°C above the determined application sealing temperature. -
Page 14: When The Controller Does Not Work Correctly
, it will not be altered, and the previously ≡ accepted value is kept. Auto Accept can be programmed in Advance Configuration 314. With Auto Accept set to ON, the altered setting will flash for 2 seconds and then automatically accepted. PIREG 545 cUL Operators Guide 2021... -
Page 15: Menu Return
-545 allows the user to compare the selected operating temperature to the actual measured temperature of the heat seal band. The user can then store the actual measured temperature, thus correcting the reference resistance (Rref) for the chosen operating PIREG 545 cUL Operators Guide 2021... -
Page 16: 8-Point Temperature-Coefficient Correction
1) it can be controlled by using a 24VDC signal at pins 22 + 20 or 2) via a controlled contact at pins 2 and 19. The preheating temperature can be set irrespective of the desired temperature. The minimum Preheat temperature is 40°C. See Section 5.8.2 PIREG 545 cUL Operators Guide 2021... -
Page 17: Start Delay
With time control set to “ON / w. start supervising”, a sealing cycle can be interrupted when the “Start” signal is no longer applied during the running sealing cycle. This monitor can be linked to various machine func- tions deemed important to achieving a quality heat sealing cycle. PIREG 545 cUL Operators Guide 2021... -
Page 18: Alarm State
Calibration Error: R20 cannot be determined Calibration Error: P-factor could not be determined Calibration Error: Reference temperature to high Calibration Error: Range of Tc correction exceeded Calibration Error: Temperature for steadiness and dy- namic to low PIREG 545 cUL Operators Guide 2021... -
Page 19: Fault Area Diagram
Menu 219) Temperature diagnosis activated, temperature too low 2.66 4, 5, or 6 Temperature diagnosis activated, temperature too high Device error Check Internal error 4.66 Controller Write/read error of memory 5.7.2. Fault Area Diagram: PIREG 545 cUL Operators Guide 2021... - Page 20 Ir signal outside tolerable range of 20…500 A Check number of turns (two or more turns required for current Turns thru CT-50 current trans- former incorrect signal less than 20 A) Internal controller fault Hardware fault (replace controller) PIREG 545 cUL Operators Guide 2021...
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Page 21: Inputs
Preheat can be activated by applying a 24VDC signal to the Preheat input (22) and GND (20). Preheat can be activated by applying a connection of the Preheat-Contact input (19) to AGND (2). PIREG 545 cUL Operators Guide 2021... -
Page 22: Autocal Start Input
Reset Input: With a high signal at the Reset input (26), the PIREG -545 is reset to the Power On ® state in the event of a fault even without switching off at the mains. PIREG 545 cUL Operators Guide 2021... -
Page 23: Set" Temperature Input
In the case of clockwise rotation on the potentiometer, the voltage should in- crease at the set value input. The chosen temperature range is imaged to the set value voltage, as described above. PIREG 545 cUL Operators Guide 2021... -
Page 24: Outputs
> 25A) based on the specific heat sealing application. Installation of an external solid state relay does not require special settings. A TOSS Applications Engineer can assist in determining whether or not an external solid-state relay (booster) will be required. -
Page 25: Relay And Output Functions - K1 Relay, K2 Relay, Output
Same as above 9 “active when ACT=SET wL” Same as above 10 “OFF” Same as above 11 "active while alarm" Same as above 12 “active while calibration OK” 13 “while tc correction” Same as above PIREG 545 cUL Operators Guide 2021... -
Page 26: Timing Charts For Relay And Output Functions
0.00…99.9 sec. generates seal phase impulse 0.00…99.9 sec. generates cool phase impulse 0.5 sec. generates end of cycle impulse PIREG 545 cUL Operators Guide 2021... -
Page 27: Timing Charts Continued
545 controller offers three levels of Security Protection designed to allow the user to limit access to the various menu settings. (See Section 7.1.) The three levels including the menu screens they protect are as follows: PIREG 545 cUL Operators Guide 2021... -
Page 28: Temperature Unit
“ * * * * “ will replace the zeros to signify that a new password has been created. Note: If a password has been established and lost, a master override password has been pre- programmed for entry in screens 405, 410 and 416. Call TOSS for instructions. 5.11.7. Temperature unit: The PIREG ®... -
Page 29: Home Screen With Time Control Off
1 or 2, if the calibration switching is acti- vated. If the measurement pause is activated, on the right side the symbol Π is showed. Line 5: Functions same as described above. PIREG 545 cUL Operators Guide 2021... -
Page 30: Alarm Screen
( ≡ 5.8.2.) for details. SETTINGS Note: The Preheat function is used to maintain the TOSS Alloy 20 Preheat temp.: 888 °C heat seal band at constant temperature between 40°C and “Set” temperature while the machine is idle. It is limited to the selected (OFF/40...300 °C ) -
Page 31: Settings Menu 103 - Start Delay
The reference temperature should be the actual temperature SETTINGS of the ambient TOSS Alloy 20 heat seal band, within the range of 0 AUTOCAL to: 20 °C - 50°C. Press the buttons to alter the reference temperature ... -
Page 32: Settings Menu 107 - Autocal Continued
temperature of the heat seal band. The text “Act” will be change to “Corr”. Press the Enter button to save. ≡ Press the Enter button again to end the Single point calibration. ≡ PIREG 545 cUL Operators Guide 2021... -
Page 33: Settings Menu 110 - 8-Point Calibration
2 seconds. Press the Menu Scroll to advance to the next Setting menu: - with Batch Counter On advances to Settings menu 113 - with Batch Counter Off advances to Home Screen. PIREG 545 cUL Operators Guide 2021... -
Page 34: Settings Menu 113 - Batch Counter Reset
ON (Configuration 227), at the selection of the “variable” Tc settings the text “variable / (Tc1, Tc2 & Tc3)” is displayed. Pressing the Menu Scroll to advance to the Configuration menu 204a. PIREG 545 cUL Operators Guide 2021... -
Page 35: Configuration Menu 204 - Variable Tc Setting
If the voltage on the Set temperature input (X23) is higher than the maximum temperature setting, the PIREG ® -545 change to error (100...888 °C ) state. Press the Menu Scroll to advance to Configuration menu 207 PIREG 545 cUL Operators Guide 2021... -
Page 36: Configuration Menu 207 - Low Temperature Deviation
Relay K1 function is programmed to generate seal phase im- CONFIGURATION pulse (5) or cooling phase impulse (6), press Menu Scroll Relay K1 OFF advance to Configuration Menu 212a to set duration time of pulse. PIREG 545 cUL Operators Guide 2021... -
Page 37: Configuration Menu 212A - K1 Impulse Duration
Analog out provides real temperature Configuration Menu 217 – Selection to activate and deactivate temperature control. The OK Temperature Diagnosis zone is set in the setting menu 207 and 208. CONFIGURATION Temperat. Diagnosis: (OFF/ON) PIREG 545 cUL Operators Guide 2021... -
Page 38: Configuration Menu 218 - Temp. Diagnosis Time Delay
Output 1 Switching Mode (“normal”) contact or break (“inverse”) contact. Show selectable setting zone. CONFIGURATION Output 1: normal (normal/inverse) Configuration Menu 225 – Selection of temperature units Temperature Unit C° or F° CONFIGURATION Temperature unit: Celsius (Celsius/Fahrenheit) PIREG 545 cUL Operators Guide 2021... -
Page 39: Configuration Menu 226 - Batch Counter-Home Screen
Line 4: Direction to Reset. Reset 8-point temperature coefficient cor- rection by pressing of button. ≡ After Reset the 8-point temperature coefficient correction a new cor- ADVANCE CONFIG. 302b rection is possibly after a new auto-calibration. Tc correction: 8 point Reset with ENTER PIREG 545 cUL Operators Guide 2021... -
Page 40: Advance Config. Menu 303 - Tc Correction Heating Time
Seal Time Count Direction a current sealing cycle. It can be selected either display of adjusted sealing time, or display counts up or down running time of sealing cycle. ADVANCE CONFIG. Seal time counting Direction (OFF/UP/DOWN) PIREG 545 cUL Operators Guide 2021... -
Page 41: Advance Config. Menu 309 - Cool Time Count Direction
Advance Config. Menu 314 – Set to "On" to automatically accept changes to values. Setting to Auto Accept Value Changes "Off" requires pressing the button to accept changes to values. ≡ ADVANCE CONFIG. Auto. accept: (OFF/ON) PIREG 545 cUL Operators Guide 2021... -
Page 42: Advance Config. Menu 315 - Total Life Cycles
In configuration menu 317a select the time delay for the change be- tween calibration 1 and 2. Advance Config. Menu 317a – Setting of the time delay at the change between the calibration 1 and Reset Input Time Delay ADVANCE CONFIG. 317a Time delay: (Off/1...99s) PIREG 545 cUL Operators Guide 2021... -
Page 43: Advance Config. Menu 318 - Autocal Input Function
In configuration menu 318a select the time delay for the change be- tween calibration 1 and 2. Advance Config. Menu 318a – Setting of the time delay at the change between the calibration 1 and AutoCal Input Time Delay ADVANCE CONFIG. 318a Time delay: (Off/1...99s) PIREG 545 cUL Operators Guide 2021... -
Page 44: Security Protection
Security Protection menu: - with Settings selected advances to Security Protec. menu 402 - with Level 1 selected advances to Security Protec. menu 407 - with Level 2 selected advances to Security Protec. menu 412 PIREG 545 cUL Operators Guide 2021... -
Page 45: Security Protection Menu 402: Settings Level, Function Selection
The display changes back to “ * * * * ” and the lock symbol will change to the unlocked symbol . Press the Menu Scroll button to return back to Security Protection menu 401. PIREG 545 cUL Operators Guide 2021... -
Page 46: Security Protection Menu 405: Settings Level, Changing Password Function
Note: To lock any level the operator must first “Change” the factory password “0000” and establish a new password. To return back to the Security Protection menu 401 without making any changes press the Menu scroll button twice. PIREG 545 cUL Operators Guide 2021... -
Page 47: Security Protection Menu 408: Level 1, Locking Function
2. Press the button to enter the second digit →press the Menu scroll button 3. Press the button to enter the third digit →press the Menu scroll button PIREG 545 cUL Operators Guide 2021... -
Page 48: Security Protection Menu 411: Level 1, Set New Password Function
→press the Menu scroll button 4. Press the button to enter the fourth digit →press the Enter button to accept the entry. (not the Menu scroll button ≡ PIREG 545 cUL Operators Guide 2021... -
Page 49: Security Protection Menu 414: Level 2, Unlocking Function
Once this occurs, follow the keystrokes below enter and accept the new password: 1. Press the button to enter the first digit →press the Menu scroll button PIREG 545 cUL Operators Guide 2021... - Page 50 Connection between outer and neutral conductor or between two outer conductors, whereby the nom- inal voltage between outer conductor and earth must not exceed 300 V. Overvoltage category: Mains frequency: 50 - 60 Hz (Frequency fluctuation: 45 … 65 Hz) PIREG 545 cUL Operators Guide 2021...
- Page 51 Supply: SELV or PELV circuit Control contact: Control contact (7) and preheating contact input (19) on the potential of the measuring side Contact voltage = 5 V Contact Contact current: = 4 mA Contact PIREG 545 cUL Operators Guide 2021...
- Page 52 Pollution class: Protection type: IP20 (*: not part of the acceptance according to UL 61010) Mounting: Mounted switchboard, cut-out 138 x 68 mm Dimensions (W x H x D): 144 x 72 x 169 mm PIREG 545 cUL Operators Guide 2021...
- Page 53 Lifetime: approx. 125 h Housing: Plastic (ABS) Dimensions (W x H x D): 60 x 120 x 26 mm Weight: 130 g Operating temperature: 0…60 °C Remark: The thermometer TM6 is no longer available. PIREG 545 cUL Operators Guide 2021...
- Page 54 Single-point TC correction: Operation of the single-point temperature coefficient correction for correcting tolerances of the temperature coefficient in only one operating point. Phone: 610-759-8883 TOSS Machine Components, Inc. Fax: 610-759-1766 539 South Main Street Email: info@tossheatseal.com Nazareth, PA 18064 USA Internet: www.tossheatseal.com PIREG 545 cUL Operators Guide 2021...
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