Toss PIREG 545 User manual

PIREG 545 cUL Operators Guide 2021
1
PIREG®-545
Operator’s Guide
539 South Main Street Phone: [phone] E-Mail: [e-mail]
Nazareth, PA 18064 Fax: [phone] Web: www.tossheatseal.com

PIREG 545 cUL Operators Guide 2021
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Table of Contents:
1. GENERAL, SAFETY AND WARNING INSTRUCTIONS ............................................................................................ 6
1.1. NOTE ON THE OPERATOR’S GUIDE ............................................................................................................................. 6
1.2. ICONS AND SYMBOLS ............................................................................................................................................... 6
1.3. GENERAL SAFETY INSTRUCTIONS ................................................................................................................................ 6
1.4. APPLICATION ......................................................................................................................................................... 6
1.5. HEAT SEAL BANDS AND GENUINE TOSS ALLOY 20® ..................................................................................................... 6
1.6. IMPULSE TRANSFORMER .......................................................................................................................................... 7
1.7. CURRENT TRANSFORMER ......................................................................................................................................... 7
1.8. LINE FILTER ............................................................................................................................................................ 7
1.9. GENERAL ASSEMBLY INSTRUCTIONS AND DIMENSIONS .................................................................................................... 7
1.10. CE CONFORMITY & CUL LISTING ............................................................................................................................. 8
1.11. MAINTENANCE..................................................................................................................................................... 9
1.12. DISPOSAL ............................................................................................................................................................ 9
2. CONTROLLER DESCRIPTION AND INSTALLATION OVERVIEW ............................................................................. 9
2.1. INSTALLATION OVERVIEW ....................................................................................................................................... 10
2.2. PIREG®-545 REAR ELECTRICAL PIN-OUT ................................................................................................................... 10
2.3. WIRING DIAGRAM FOR THE PIREG®-545 .................................................................................................................. 11
2.4. WIRING DIAGRAM FOR THE PIREG®-545 WITH EXTERNAL SOLID-STATE RELAY (BOOSTER) ................................................ 11
3. INSTALLATION AND COMMISSIONING .............................................................................................................12
3.1. INSTALLATION ...................................................................................................................................................... 12
3.2. CONFIGURING THE SECONDARY VOLTAGE AND CURRENT ............................................................................................... 12
3.3. CONFIGURING THE SETTINGS ................................................................................................................................... 12
3.4. CONNECTING THE PIREG®-545 .............................................................................................................................. 12
3.5. EXTERNAL SOLID STATE RELAY (BOOSTER) ................................................................................................................. 13
3.6. CONTROL INPUTS .................................................................................................................................................. 13
3.7. CONNECTING TO THE MAINS VOLTAGE ...................................................................................................................... 13
3.8. THE TOSS ALLOY 20 & SUITABLE HEAT SEAL BAND MATERIALS ................................................................................... 13
3.9. BURNING IN THE GENUINE TOSS ALLOY 20 HEAT SEAL BAND ........................................................................................ 13
3.10. CURRENT TRANSFORMER ..................................................................................................................................... 13
3.11. WHEN THE CONTROLLER DOES NOT WORK CORRECTLY ............................................................................................... 14
4. OPERATION ......................................................................................................................................................14
4.1. BUTTONS ............................................................................................................................................................ 14
4.1.1. Changing between menu levels: .............................................................................................................. 14
4.1.2. Setting of numeric values: ....................................................................................................................... 14
4.1.3. Setting of functions: ................................................................................................................................. 14
4.1.4. Accepting numeric values or functions: ................................................................................................... 14
4.1.5. Menu return: ............................................................................................................................................ 15
4.1.6. Brightness: ............................................................................................................................................... 15
4.1.7. Edit Prevention: ....................................................................................................................................... 15
4.1.8. Locking: .................................................................................................................................................... 15
5. FUNCTIONS ......................................................................................................................................................15
5.1. CONTROL ............................................................................................................................................................ 15
5.1.1. Setting temperature coefficients: ............................................................................................................ 15
5.1.2. Temperature range: ................................................................................................................................. 15
5.1.3. Transformer type: .................................................................................................................................... 15
5.1.4. Reference temperature: ........................................................................................................................... 15
5.2. AUTO CALIBRATION AND TEMP. COEFFICIENT CORRECTION: ......................................................................................... 15
5.2.1. Establishing the ambient temperature’s reference resistance (Rref): ..................................................... 15
5.2.2. Single-point temperature coefficient correction: ..................................................................................... 15
5.2.3. 8-Point Temperature-coefficient correction: ........................................................................................... 16
5.3. OFF-STATE .......................................................................................................................................................... 16
5.4. ON STATE............................................................................................................................................................ 16
5.5. TIME CONTROL ..................................................................................................................................................... 16
5.5.1. Preheating: .............................................................................................................................................. 16
5.5.2. Start delay: .............................................................................................................................................. 17

PIREG 545 cUL Operators Guide 2021
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5.5.3. Sealing time: ............................................................................................................................................ 17
5.5.4. Cooling phase: ......................................................................................................................................... 17
5.6. MONITORING ...................................................................................................................................................... 17
5.6.1 Temperature diagnostic: .......................................................................................................................... 17
5.6.2. Temperature rise monitor: ....................................................................................................................... 17
5.6.3. Start signal monitor: ................................................................................................................................ 17
5.7. ALARM STATE ...................................................................................................................................................... 18
5.7.1. Possible Alarms: ....................................................................................................................................... 18
5.7.2. Fault Area Diagram: ................................................................................................................................ 19
5.8. INPUTS ............................................................................................................................................................... 21
5.8.1. Start inputs: ............................................................................................................................................. 21
5.8.2. Preheat inputs: ........................................................................................................................................ 21
5.8.3. Autocal Start Input: ................................................................................................................................. 22
5.8.4. Reset Input: .............................................................................................................................................. 22
5.8.5. “Set” Temperature Input: ........................................................................................................................ 23
5.9. OUTPUTS ............................................................................................................................................................ 24
5.9.1. Actual Temperature Output: ................................................................................................................... 24
5.9.2. Alarm output: .......................................................................................................................................... 24
5.9.3. Booster output: ........................................................................................................................................ 24
5.9.4. K1 and K2 - Control relay outputs: ........................................................................................................... 24
5.9.5. Output 1 - Message relay: ....................................................................................................................... 24
5.10. RELAY AND OUTPUT FUNCTIONS - K1 RELAY, K2 RELAY, OUTPUT 1 ............................................................................. 25
5.10.1. Timing Charts for Relay and Output Functions ...................................................................................... 26
5.10.1. Timing Charts Continued: ...................................................................................................................... 27
5.11. DISPLAY FUNCTIONS ............................................................................................................................................ 27
5.11.1. Languages: ............................................................................................................................................ 27
5.11.2. Brightness: ............................................................................................................................................. 27
5.11.3. Hold mode: ............................................................................................................................................ 27
5.11.4. Batch and Cycle Counters: ..................................................................................................................... 27
5.11.5. Recipe Storage: ...................................................................................................................................... 27
5.11.6. Security Protection: ................................................................................................................................ 27
5.11.7. Temperature unit: .................................................................................................................................. 28
6. MENU STRUCTURE ...........................................................................................................................................28
6.1. START ................................................................................................................................................................ 28
6.2. HOME SCREEN ..................................................................................................................................................... 28
6.2.1. Home Screen with time control ON ......................................................................................................... 28
6.2.2. Home Screen with time control OFF ........................................................................................................ 29
6.2.3. Alarm Screen ............................................................................................................................................ 30
6.3. SETTING-MENU .................................................................................................................................................... 30
Settings Menu 101 – Seal Temperature............................................................................................................. 30
Settings Menu 102 – Preheat Temperature....................................................................................................... 30
Settings Menu 103 – Start Delay ....................................................................................................................... 31
Settings Menu 104 – Sealing Time ..................................................................................................................... 31
Settings Menu 105 – Cooling Mode ................................................................................................................... 31
Settings Menu 106 – Hold Mode ....................................................................................................................... 31
Settings Menu 107 - AutoCal ............................................................................................................................. 31
Settings Menu 107 – AutoCal CONTINUED ........................................................................................................ 32
Settings Menu 108 - AutoComp ......................................................................................................................... 32
Settings Menu 109 - Single Point Calibration .................................................................................................... 32
Settings Menu 110 – 8-Point Calibration ........................................................................................................... 33
Settings Menu 111 – Recall Recipe .................................................................................................................... 33
Settings Menu 112 – Save Recipe ...................................................................................................................... 33
Settings Menu 113 – Batch Counter Reset ........................................................................................................ 34
6.4. CONFIGURATION-MENU ......................................................................................................................................... 34
Configuration Menu 201 - Language ................................................................................................................. 34
Configuration Menu 202 – Recall / Save Settings .............................................................................................. 34
Configuration Menu 203 – Alloy Tc Selection / ppm.......................................................................................... 34
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
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Configuration Menu 207 – Low Temperature Deviation ................................................................................... 36
Configuration Menu 208 – High Temperature Deviation .................................................................................. 36
Configuration Menu 209 – Time Control ........................................................................................................... 36
Configuration Menu 210 – Cool Mode Selection ............................................................................................... 36
Configuration Menu 211 – Start of Sealing Timer ............................................................................................. 36
Configuration Menu 212 – K1 Relay Function ................................................................................................... 36
Configuration Menu 212a – K1 Impulse Duration ............................................................................................. 37
Configuration Menu 213 – “Hand” Button Function ......................................................................................... 37
Configuration Menu 214 – Seal Cycles (Resettable) .......................................................................................... 37
Configuration Menu 215 – Alarm Relay Switch Mode ....................................................................................... 37
Configuration Menu 216 – Output 0-10 VDC / Ref. ........................................................................................... 37
Configuration Menu 217 – Temperature Diagnosis .......................................................................................... 37
Configuration Menu 218 – Temp. Diagnosis Time Delay ................................................................................... 38
Configuration Menu 219 – Heat-Up Time Out ................................................................................................... 38
Configuration Menu 222 – Output 1 Function ................................................................................................... 38
Configuration Menu 222a – Output 1 Impulse Duration ................................................................................... 38
Configuration Menu 223 – Output 1 Switching Mode ....................................................................................... 38
Configuration Menu 225 – Temperature Unit C° or F°....................................................................................... 38
Configuration Menu 226 – Batch Counter-Home Screen ................................................................................... 39
Configuration Menu 227 – Advance PIREG Features ......................................................................................... 39
6.5. ADVANCED CONFIGURATION MENU .......................................................................................................................... 39
Advance Config. Menu 301 – Tc Correction ....................................................................................................... 39
Advance Config. Menu 302a – Single Point Correction Reset ............................................................................ 39
Advance Config. Menu 302b – 8-Point Correction Reset ................................................................................... 39
Advance Config. Menu 303 – Tc Correction Heating Time ................................................................................ 40
Advance Config. Menu 304 – P-Factor Correction ............................................................................................. 40
Advance Config. Menu 305 – Calibration Compare Time .................................................................................. 40
Advance Config. Menu 307 – K2 Relay Function ............................................................................................... 40
Advance Config. Menu 307a – K2 Impulse Duration ......................................................................................... 40
Advance Config. Menu 308 – Seal Time Count Direction ................................................................................... 40
Advance Config. Menu 309 – Cool Time Count Direction .................................................................................. 41
Advance Config. Menu 310 – Heating Ramp-Up ............................................................................................... 41
Advance Config. Menu 311 – Transformer Type Selection ................................................................................ 41
Advance Config. Menu 312 – Menu Return to Home Screen ............................................................................. 41
Advance Config. Menu 313 – Locking Function (ON/OFF) ................................................................................. 41
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. Menu 317a – Reset Input Time Delay ..................................................................................... 42
Advance Config. Menu 318 – AutoCal Input Function ....................................................................................... 43
Advance Config. Menu 318a – AutoCal Input Time Delay ................................................................................. 43
7. SECURITY PROTECTION.....................................................................................................................................44
7.1. SECURITY PROTECTION LEVELS ................................................................................................................................ 44
7.2. SECURITY PROTECTION MENUS ............................................................................................................................... 44
7.2.1 Security Protection menu 401: Security level selection ............................................................................. 44
7.2.2. Security Protection menu 402: Settings Level, function selection ............................................................ 45
7.2.3. Security Protection menu 403: Settings Level, locking function .............................................................. 45
7.2.4. Security Protection menu 404: Settings Level, unlocking function .......................................................... 45
7.2.5. Security Protection menu 405: Settings Level, changing password function ........................................... 46
7.2.6. Security Protection menu 406: Settings Level, set new password function ............................................. 46
7.2.7. Security Protection menu 407: Level 1, function selection ...................................................................... 46
7.2.8. Security Protection menu 408: Level 1, locking function ......................................................................... 47
7.2.9. Security Protection menu 409: Level 1, unlocking function ..................................................................... 47
7.2.10. Security Protection menu 410: Level 1, changing password function ................................................... 47
7.2.11. Security Protection menu 411: Level 1, set new password function ..................................................... 48
7.2.12. Security Protection menu 412: Level 2, function selection .................................................................... 48
7.2.13. Security Protection menu 413: Level 2, locking function ....................................................................... 48
7.2.14. Security Protection menu 414: Level 2, unlocking function ................................................................... 49
7.2.15. Security Protection menu 415: Level 2, changing password function ................................................... 49
7.2.16. Security Protection menu 416: Level 2, set new password function ...................................................... 49

PIREG 545 cUL Operators Guide 2021
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8. TECHNICAL DATA ..............................................................................................................................................50
8.1. SCREEN SYMBOLS ................................................................................................................................................. 50
8.2. CONTROLLER ....................................................................................................................................................... 50
8.1.1. Standards - CE marking ........................................................................................................................... 53
8.3. CURRENT TRANSFORMER........................................................................................................................................ 53
8.4. SEALING TRANSFORMER ......................................................................................................................................... 53
8.5. EXTERNAL THERMOMETER DTM3000 ..................................................................................................................... 53
8.6. ORDERING CODES ................................................................................................................................................. 54
8.7. SPARE PARTS ....................................................................................................................................................... 54
9. APPLICATION NOTE ..........................................................................................................................................54
9.1. APPLICATION INSTRUCTIONS ................................................................................................................................... 54

PIREG 545 cUL Operators Guide 2021
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1. General, safety and warning instructions
1.1. Note on the Operator’s Guide
The purpose of this Operator’s Guide is to ensure optimum installation, commissioning, operation and
maintenance of the PIREG
®
-545 and must be read prior to carrying out any of the actions described.
Keep the operator’s guide handy and accessible to all users for possible referencing. Pass this guide on
to future users of the PIREG
®
-545.
All necessary settings are described in this operator’s guide. Should difficulties nevertheless arise during
commissioning or operation, please do not carry out any unauthorised manipulations. You could put your-
self and others at risk as well as jeopardize your warranty claim. In such cases, please contact us immedi-
ately:
Phone: [phone]
TOSS Machine Components, Inc.
539 South Main Street
Nazareth, PA 18064 USA
Fax: [phone]
Email: [e-mail]
Internet: www.tossheatseal.com
1.2. Icons and symbols
Danger:
Indicates a hazard that could result in personal injury. Whenever this symbol is used,
the device description must be consulted,
and the accompanying instructions must be observed
and followed in order to avoid hazards.
Danger:
Indicates a hazard due to electrical current. Failure to observe the safety instructions
may result in serious or fatal injuries.
Danger: Indicates a hazard due to hot surfaces or burn up that could result in personal injury.
Note:
Indicates particularly important information which, if ignored, can lead to material damage,
for example.
1.3. General safety instructions
The safety instructions and warnings given in this description must be followed to guarantee safe
operation of the equipment. The equipment can be operated without impairing the operational
reliability if the conditions stated in the technical specifications are observed.
The equipment may only be installed and started-up by suitably trained personnel.
Maintenance and repair of the equipment may only be carried out by trained personnel, who are
familiar with the dangers and guarantee conditions.
1.4. Application
The PIREG
®
-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.
1.5. Heat Seal Bands and Genuine TOSS Alloy 20®
A basic precaution for the functioning and safe operation of the complete heat sealing system is the use of
suitable heat seal bands such as genuine TOSS Alloy 20 heat seal bands.
The positive temperature coefficient of the heat seal band must be equal or greater than the positive tem-
perature coefficient set on the PIREG
®
-545. This appropriate temperature coefficient of the heat seal band
must be set on the PIREG
®
-545 by means of the built-in display. The temperature coefficient of the heat
seal band must be positive over the entire temperature range.
Caution: Using heat seal bands with too low a temperature coefficient or
adjusting the controller
to a temperature coefficient that is too high, can result in uncontrolled overheating or
the burning
out of the heat seal band.
Heat seal bands connected in parallel must be strictly symmetrical and performed in such a way that no
over-current arises if two heat seal bands on opposite sides should touch.

PIREG 545 cUL Operators Guide 2021
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If series-connected heat seal bands must be used, the effect on the over-current reaction if two sealing
bands on opposite side should touch needs to be taken into consideration.
1.6. Impulse Transformer
The sealing transformer must be configured according to EN 61558 (VDE 0570) resp. UL 5085 (isolating
transformer with reinforced isolation) and in a single-chamber design
Caution: There must be sufficient protection against accidental contact if the transformer is in-
stalled in a machine frame. Furthermore, ensure that water, cleaning liquids or conducting liquids
do not come into contact with the transformer. The conductor wiring c
ross sections should be
designed to match the actual currents. Non-
observance of these notes may result in impairment
of the electrical safety.
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  240 ms.
Measuring impulses continue while the PIREG
®
-545 is in the OFF state. Therefore, the higher the second-
ary voltage for a given heat seal band the greater the difference may be between the actual resting tem-
perature and the ambient temperature.
1.7. Current Transformer
The current transformer is an essential part of the control system. Only the Toss CT-50
current
transformers may be used. The current transformer may only be operated with ballast resistance.
The ballast resistance is integrated into the PIREG
®
-545. The cu
rrent transformer must be
mounted in such a way that magnetic leakage fields from the sealing transformer or other leakage
fields do not affect the measurement.
Caution: The used cable to the heating conductor can heat up the current transformer.
1.8. Line filter
A suitable line filter must be used to comply with the EMC directives listed in section 1.10. This guaran-
tees compliance with the limit value for interference emission and are an essential component to the CE
mark. The correct specification of the line filter is determined by the current load of the specific heat seal-
ing application.
This information can be found on the TOSS application report. It is important that the filter’s supply wires
not be run parallel with the filter’s output wires.
1.9. General assembly instructions and dimensions
The PIREG
®
-545 resistance temperature controller is only suited for use in an electrical cabinet. Open
operation is not permitted. The controller is designed for mounting in a control panel and the current trans-
former is mounted on a 35mm mounting rail as per EN 60715 (EN 50022). When assembling the controller
on the control panel, there must be a distance of at least 20mm away from any adjacent devices. Heat
dissipation from neighboring devices must be taken into account (note the ambient temperature specifica-
tions).

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PIREG
®
-545 Temperature Controller
Current Transformer CT -50 (Section 1.7.)
1.10. CE Conformity & cUL listing
2014/35/EU, Low voltage Directive
- EN 61010-1:2011-07,
Safety requirements for electrical equipment, control, and laboratory use.
2014/30/EU, Electromagnetic compatibility Directive
- EN 61000-6-2:2016-05,
Electromagnetic compatibility (EMC) – Part 6-2: Generic standards - Immunity for industrial environ-
ments
- EN 61000-6-3:2011-09,
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
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cUL certification:
- UL61010-1 and CAN/CSA C22.2 No. 61010-1-12:
Electrical Equipment For Measurement, Control, and Laboratory Use; Part 1: General Requirements
- UL61010-2-030 and CAN/CSA C22.2 No. 61010-2-030-18:
Electrical Equipment For Measurement, Control, and Laboratory Use; Part 2-030 Particular requirements
for equipment having testing or measuring circuits
1.11. Maintenance
The PIREG
®
-545 resistance temperature controller does not require any special maintenance. However,
an occasional check or tightening of the connection terminals is recommended. Dust deposits on the con-
troller can be removed with dry compressed air once the power has been switched off.
1.12. Disposal
Do not dispose of the device with household waste! The PIREG
®
-545
and its components must
be disposed of via the local collection points for electronic waste in accordance with the WEEE
Directive 2012/19/EU on waste electrical and electronic equipment.
Incorrect disposal can pose a risk to the environment. The PIREG
®
-545
, its components and
packaging materials must be disposed of in accordance with national waste treatment and dis-
posal regulations.
2. Controller Description and Installation Overview
The PIREG
®
-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.
NOTE: Some examples of heat sealing application include, bag/pouch sealing, vertical or horizontal
form/fill/seal, film splicing, custom port sealing, tube sealing, and seaming non-woven materials.
The impulse transformer is used by the PIREG
®
-545 on the primary side. The heat seal band is fed from
the secondary side of the transformer. As the heat seal band resistance changes with temperature, the
measuring signals are received directly from the heat seal band and are made available to the controller at
rate of 50 times per second when operated at 50Hz or at a rate of 60 times a second when operated at
60Hz.
The PIREG
®
-545 temperature controller has four control inputs and three relay outputs that can control
various functions of the heat sealing machine. In addition, there is an alarm output.
The temperature coefficient of genuine TOSS Alloy 20 heat seal band material, or suitable heat seal band
material must be positive. Its resistance increases when it is heated. This change in resistance is used for
temperature control. The temperature controller measures and regulates the resistance of the heat seal
band. The actual temperature is determined by measuring the voltage and current to calculate its temper-
ature reference resistance (Rref).
NOTE: TOSS Alloy-20 heat seal bands can be straight or contoured shaped to provide flat, uniform
sealing or they can be round, beaded, or T-profiled to perform a seal and cut operation. Seal and
cut can also be performed in contoured shapes. Ask your TOSS applications engineer for more
information.
The PIREG
®
-545 can be easily operated with the built-in display unit. An OLED module with five lines
containing twenty-one digits each is used for the display. The PIREG
®
-545 can operate up to a temperature
range as high as 500°C.
During auto-calibration, the controller sets itself to the secondary voltage of the transformer and the current
through the heat seal band. The secondary voltage of the transformer may be within a range of 1...80 V.
Higher secondary voltage ranges are possible with the use of TOSS series resistor. The current measured
with a current transformer can range from 20 to 400A.
The PIREG
®
-545 performs the auto-calibration process within a variable ambient temperature range of 0-
50°C. During this process, the actual ambient temperature must be set in the controller.
The PIREG
®
-545 provides a measurement pause function. During the measurement pause, the PIREG
®
-
545 stops the resistance measurement making it possible to interrupt the heat seal band circuit without
generating an alarm. The measurement pause is controlled using either the reset or calibration-start inputs.

PIREG 545 cUL Operators Guide 2021 10
2.1. Installation Overview
2.2. PIREG®-545 rear electrical pin-out