Toss PIREG-D2 Manuale utente

Opera ing Ins ruc ions

Temperature Controller PIREG®-D

Wi h kind regards

GmbH & Co. KG

-Verpackungssys eme-

Danziger S raße 15

D-35418 Al en-Buseck

Tel.: +49 (0) 64 08 - 90 91

- 0

Fax: +49 (0) 64 08 - 43 55

E-Mail: info@ oss-gmbh.de

In erne : www. oss-gmbh.de

PIREG-D

Device description:

Resistance Temperature Controller

Applications:

Packaging machine for sealing

plas ic films.

Con roller PIREG-D2

Curren ransformer PIREG-CT-50

Contents:

1. General, safety and warning instructions 3

1.1. ote on the device description 3

1.2. Icons and symbols 3

1.3. General safety instructions 4

1.4. Application 4

1.5. ote on the heating conductor 4

1.6. ote on the sealing transformer 4

1.7. ote on the current transformer 5

1.8. General assembly instructions 5

1.9. Maintenance 5

1.10. Validity 5

2. Short description 5

3. Functions 6

3.1. Control 6

3.1.1. Hea -up ramp 6

3.1.2. Se ing empera ure coefficien s 7

3.1.3. Calibra ion reference ime 7

3.1.4. Tempera ure range 7

3.1.5. Calibra ion mode 7

3.1.6. Transformer ype 7

3.1.7. Reference empera ure 7

3.1.8. Tempera ure coefficien correc ion 7

3.2. Calibration 7

3.2.1. Ini ialisa ion 8

3.2.2. Calibra e inpu amplifier 8

3.2.3. De ermining he phase shif 8

3.2.4. De ermine reference resis ance 8

3.2.5. Tempera ure comparison ime 8

3.2.6. Check reference resis ance 8

3.2.7. De ermine he P-fac or 8

3.2.8. Se ini ialising remanence 9

3.2.9. Tempera ure-coefficien correc ion 9

3.2.10. Single-poin c correc ion 10

3.2.11. P-fac or correc ion 11

3.3. Off-state 11

3.2.1. Measuremen pulse-pause 11

3.2.2. Calibra ion swi ching 11

3.4. On state 12

3.5. Sequence control 12

3.5.1. Prehea ing 12

3.5.2. S ar delay 12

3.5.3. Sealing ime 12

3.5.4. Cooling phase 12

3.6. Monitoring 12

3.6.1. Tempera ure moni or 12

3.6.2. Hea ing moni or 12

3.6.3. S ar moni or 12

3.6.4. Communica ion moni or 12

3.7. Error state 12

3.7.1. Possible errors 13

3.8. Relay functions 14

3.8.1. Tempera ure func ion 14

3.8.2. Sequence func ion 14

3.8.3. Time pulse func ion 14

3.9. Display functions 14

3.9.1. Languages 14

3.9.2. Brigh ness 14

3.9.3. Hold mode 14

3.9.4. Cycle coun er 14

3.9.5. Saving 14

3.9.6. Releases 14

3.9.7. Tempera ure uni 15

4. Operation 15

4.1. Keys 15

4.1.1. Cursor 15

4.1.2. Se ing numerical values 15

4.1.3. Selec ing func ions 15

4.1.4. Accep ance of he se ings 15

4.1.5. Menu change 15

4.1.6. Menu re urn 15

4.1.7. Locking 15

4.1.8. Execu ion preven ion 16

4.2. Leuchtdioden 16

4.2.1. Power 16

4.2.2. Hea 16

4.2.3. Alarm 16

4.3. Inputs 16

4.3.1. S ar inpu s 16

4.3.2. Prehea inpu s 16

4.3.3. Calibra ion S ar Inpu 16

4.3.4. Rese Inpu 16

4.3.5. Measuremen pause 16

4.3.6. Calibra ion swi ching 16

4.3.8. Se value inpu 16

4.4. Outputs 17

4.4.1. Ac ual Value Ou pu 17

4.4.2. Message relay ou pu 17

4.4.3. Con rol relay ou pu s 17

4.4.4. Alarm ou pu 17

4.4.5. ELR ou pu 17

4.5. Interfaces 17

5. Menu structure 18

5.1. Switching on 18

5.2. Working menu 18

5.2.1. Working menu wi hou sequence con r. 18

5.2.2. Working menu wi h sequence con rol 18

5.2.3. Symbols for he opera ing s a us 19

5.2.4. Error menu 19

5.2.5. Kalibrierungs-Auswahlmenü 20

5.2.5.1. Calibra ion Informa ion menu 20

5.3. Selection menu 20

5.4. Sequence Control menu 21

5.4.1. Prehea menu 21

5.4.2. S ar Func ion menu 21

5.4.3. S ar Delay menu 21

5.4.4. Welding Time menu 22

5.4.5. Cooling Phase menu 22

5.5. Monitoring menu 22

5.5.1. Tempera ure moni oring menu 23

5.5.2. Hea ing moni oring menu 23

5.6. In-/Output settings menu 23

5.6.1. Relais se ing menu 23

5.6.1.1. Message Relay se ings menu 23

5.6.1.1.1. Message Relay Temp. func. menu 24

5.6.1.1.2. Message Relay Seq. func. menu 24

5.6.1.1.3. Message Relay Time P. func. m. 24

5.6.1.2. Con rol Relay se ings menu 24

5.6.1.2.1. Con rol Relay Temp. func. menu 25

5.6.1.2.2. Con rol Relay Seq. func. menu 25

5.6.1.2.3. Con rol Relay Time P. func ion m. 25

5.6.1.3. Alarm Relay se ings menu 25

5.6.1.4. Relay Ou pu s s a us menu 26

5.6.2. Inpu se ing menu 26

5.6.2.1. Prehea ing inpu se ing menu 26

5.6.2.2. S ar inpu se ing menu 26

5.6.2.3. Calibra ion-S ar inpu se ing menu 26

5.6.2.4. Rese inpu se ing menu 26

5.7. Controller setting menu 27

5.7.1. Tc se ings menu 27

5.7.1.1. Variable Tc se ings menu 27

5.7.2. Tempera ure se ings menu 27

5.7.3. Time se ings menu 27

5.7.4. Calibra ion se ings menu 28

5.7.5. Se value se ings menu 28

5.8. Display settings menu 28

5.8.1. Se ings menu for lang. and brigh ness 28

5.8.2. Hold Mode menu 29

5.8.3. Opera ing menu 29

5.8.4. Releases menu 29

5.9. Save menu 30

5.9.1. Parame er se s menu 30

5.9.2. Fac ory Se ings menu 30

5.10. Informations-Menü 30

6. Installation and commissioning 31

6.1. Installation 31

6.2. Configuring the settings 31

6.3. Connection of the PIREG-D2 31

6.4. Control inputs 31

6.5. Connecting to the mains voltage 31

6.6. Burning in the heating conductor 32

6.7. When the contr.r does not work corr. 32

6.8. Current Transformer 32

7. The heating conductor 32

8. Technical data 33

8.1. Controller 33

8.2. Current transformer 35

8.3. Sealing transformer 35

8.4. External thermometer DTM3000 36

8.5. Ordering codes 36

8.6. Housing 37

8.6.1. PIREG-D2 housing 37

8.6.2. Curren ransformer housing 37

8.7. Spare parts 37

9. Connection diagrams 38

9.1. PIREG-D2 with ext. solid-state relay 38

9.2. PIREG-D2 with internal thyristors 38

9.3. RS232 / RS485 connection - interface 38

10. Application note 39

10.1. Application instructions 39

11. Disposal 39

1. General, safety and warning instructions

1.1. ote on the device description

The purpose of his device descrip ion is o ensure op imum ins alla ion, commissioning, opera ion and

main enance of he PIREG-D2 and mus be read prior o carrying ou any of he ac ions described. Keep

he device descrip ion handy and accessible o all users for possible referencing. Pass his manual on o

fu ure users of he PIREG-D2.

All necessary se ings are described in his device descrip ion. Should difficul ies never heless arise dur-

ing commissioning or opera ion, please do no carry ou any unau horised manipula ions. You could pu

yourself and o hers a risk as well as jeopardize your warran y claim. In such cases, please con ac us

immedia ely:

GmbH & Co. KG Phone: +49 (0) 64 08 - 90 91 - 0

-Verpackungssys eme- Fax: +49 (0) 64 08 - 43 55

Danziger S raße 15 E-mail: info@ oss-gmbh.de

D-35418 Al en-Buseck In erne : www. oss-gmbh.de

1.2. Icons and symbols

Danger

(EN)

Indica es a hazard ha could resul in personal injury. Whenever his symbol is

used, he device descrip ion mus be consul ed and he accompanying ins ruc ions mus be

observed and followed in order o avoid hazards.

Danger (FR): Indique un danger pouva

n en rainer des a ein es à la san é des personnes.

Lorsque ce symbole es u ilisé, la descrip ion de l’appareil doi ê re consul ée e les indica ions

doiven ê re observées e respec ées afin d’évi er ou e mise en danger.

Danger

(EN)

Indica es a hazard due o elec rical curren . Failure o observe he safe y ins ruc-

ions may resul in serious or fa al injuries.

Danger (FR): Indique un danger d’élec rocu ion. Un non-

respec de ces indica ions de sécuri é

en raine un danger de blessures graves, voire mor elles.

Danger

(EN)

Indica es a hazard due o ho surfaces or burn up ha could resul in personal

injury.

Danger (FR): Indique un danger dû aux surfaces brûlan es, voire rougeoyan es pouvan en-

rainer des a ein es à la san é des personnes.

ote

(EN)

Indica es par icularly impor an informa ion which, if ignored, can lead o ma erial

damage, for example.

Indications (FR):

Indique une informa ion par iculièremen impor an e pouvan en rainer des

dégâ s ma ériels en cas de non-respec .

1.3. General safety instructions

E :

The safe y ins ruc ions and warnings given in his descrip ion mus be followed o guaran-

ee safe opera ion of he equipmen . The equipmen can be opera ed wi hou impairing he op-

era ional reliabili y if he condi ions s a ed in he echnical specifica ions are observed.

The equipmen may only be ins alled and s ar ed-up by sui ably rained personnel.

in enance and repair of he equipmen may only be carried ou by rained personnel, who are

familiar wi h he dangers and guaran ee condi ions.

FR:

Les indica ions e mises en garde con enues dans ce e descrip ion doiven ê re respec ées

afin de garan ir

un fonc ionnemen sûr. Si les consignes de sécuri é de fonc ionnemen son

respec ées, l’appareil peu ê re exploi é aux condi ions men ionnées dans les données ech-

niques.

Ce appareil ne peu ê re ins allé e mis en service que par un personnel qualifié

en echnique

élec ronique !

Les ravaux d’en re ien e de répara ion ne peuven ê re effec ués que par des personnes

formées e spécialis es familiarisées avec les dangers liés à l’appareil e les condi ions de gar-

an ie.

1.4. Application

E :

The PIREG-D

2 resis ance empera ure con roller may only be used for he hea ing and

empera ure con rol of hea ing conduc ors as specified via isola ing ransformers in accordance

wi h he regula ions, no es and warnings con ained in his descrip ion.

Non-

observance of he ins ruc ions or incorrec use of he equipmen can resul in impairmen of

he safe y or overhea ing of he hea ing conduc or, he elec rical wiring or he ransformer.

FR: Le régula eur de empéra ure à résis ance PIREG-D2 ne doi ê re u ilisé que pour le chauf-

fage e la régula ion de empéra ure de conduc eurs de chaleur expressémen conçus à ce

effe par l'in ermédiaire de ransforma eurs de sépara ion conformémen aux prescrip ions, indi-

ca ions e mises en garde men ionnés dans ce e descrip ion.

Le non-respec ou l'u ilisa ion non conforme peu comprome re la sécuri é ou en rainer le sur-

chauffe des conduc eurs de chaleur, des câbles élec riques, du ransforma eur, e c.

1.5. ote on the heating conductor

A basic precondi ion for he func ion and safe opera ion of he comple e hea ing sys em is he applica ion

of sui able hea ing conduc ors.

The posi ive empera ure coefficien of he hea ing conduc or used mus be equal or grea er han he

posi ive empera ure coefficien se a he PIREG-D2. The appropria e empera ure coefficien of he hea -

ing conduc or mus be se on he display uni of he PIREG-D2 or via he in erface. The empera ure coef-

ficien of he hea ing conduc or mus be posi ive over he en ire empera ure range.

Cau

tion

(EN)

Using hea ing conduc ors wi h oo low a empera ure coefficien , or adjus ing he

con roller o a empera ure coefficien ha is oo high, can resul in uncon rolled overhea ing or

melting of he hea ing conduc or.

Attention (FR):

Si un conduc eur de chaleur es u ilisé avec un pe i coefficien de empéra ure

ou qu’un coefficien de empéra ure rop grand es réglé sur le régula eur, les conduc eurs de

chaleur von chauffer de manière incon rôlée e peuven aller jusqu’à fondre.

Tempera ure regula ion of hea ing conduc ors connec ed in parallel mus be more precise han of hea ing

conduc ors connec ed in series. However, he wiring mus be s ric ly symme rical and performed in such a

way ha no overcurren arises when wo hea ing conduc ors on opposi e sides con ac each o her.

If series-connec ed hea ing conduc ors have o be used, he effec on he overcurren reac ion should be

aken in o considera ion if wo opposi e sealing bands ouch each o her.

1.6. ote on the sealing transformer

The sealing ransformer mus be configured according o EN 61558 (VDE 0570) resp. UL 5085 (isola ing

ransformer wi h reinforced isola ion) and in a single-chamber design. All ypes and designs ha comply

wi h he s andards can be used as sealing ransformers. The induc ion in he ransformer's iron core mus

no be reduced as is normally he case wi h primary side hyris or opera ion. A ransformer wi h low losses

are disrup ed less on he secondary side han wi h ransformers ha have low energizing curren s. Thus

in applica ions wi h shor hea ing and sealing imes, s iff and generally larger ransformers should be

used. Where a grea deal of sealing is o be performed, a ransformer wi h a primary vol age of 400 V is

advan ageous, because his way, he swi ching capaci y of he PIREG-D2's in ernal ac ua or is more likely

o be sufficien and an ex ernal ac ua or wi h solid-s a e relay will no have o be used.

Caution

(EN)

There mus be sufficien pro ec ion agains acciden al con ac if he ransformer

is ins alled in a machine frame. Fur hermore, ensure ha wa er, cleaning liquids or conduc ing

liquids do no come in o con ac wi h he ransformer. The conduc or wiring c

ross sec ions

should be designed o ma ch he ac ual curren s. Non-

observance of hese no es may resul in

impairmen of he elec rical safe y.

Attention (FR):

Si le ransforma eur es placé dans le corps de la machine, une pro ec ion

suffisan e con re les

con ac s acciden els doi ê re prévue. De plus, il convien d’empêcher l'eau,

les solu ions de ne oyage ou les liquides conduc eurs d’en rer en con ac avec le ransfo

ma eur. Les sec ions des câbles doiven ê re conçues en fonc ion des couran s réels. Le non

respec de ces ins ruc ions comprome la sécuri é élec rique.

For bes resul s, he ransformer's performance and he secondary vol age mus be sui ed o he hea ing

conduc or. A shor hea -up period is reached wi h of a high ransformer ou pu vol age. However, he vol -

age selec ed should no be oo large so ha no less han 12 con roller measuremen s are needed for a

arge empera ure increase of 300°C when hea ing up (hea -up period  240 ms). For smaller hea -up

curves, correspondingly fewer measuremen s are necessary. (The PIREG-D2 akes a measuremen eve-

ry 20 ms while hea ing).

The larger he ransformer's secondary vol age for a given hea ing conduc or, he more energy is fed in o

he hea ing conduc or, even in he OFF s a e. This is done by means of empera ure measuring impulses,

which he con roller regularly sends o he hea ing conduc or. Therefore, he higher he secondary vol age

of he ransformer he grea er is he difference be ween he res ing empera ure and he ambien empera-

ure in he OFF s a e.

1.7. ote on the current transformer

E :

The curren ransformer is an essen ial par of he con rol sys em. Only Toss curren rans-

formers may be used. The curren ransformer may only be opera ed wi h ballas resis ance.

The ballas resis ance is in egra ed in o he PIREG-D2. The curren ransformer mus be moun -

ed in such a way ha magne ic leakage fields from he sealing ransformer or o her leakage

fields do no affec he measuremen .

FR: Le ransforma eur de couran fai par ie du sys ème de régula ion. Seuls les ransfor-

ma eurs de couran Toss peuven ê re u ilisés. Le ransforma eur de couran ne doi ê re u ilisé

qu'avec une résis ance ohmique apparen e. La résis ance ohmique apparen e es in égrée dans

le PIREG-D2. Le ransforma eur de couran doi ê re mon é de elle sor e que les champs mag-

né iques de dispersion du ransforma eur de soudage ou d'au res champs de dispersion n'influ-

encen pas la mesure.

Caution

(EN)

The used cable o he hea ing conduc or can hea up he curren ransformer.

Attention (FR): Le condui u ilisé allan vers le conduc eur de chaleur peu chauffer le ransfor-

ma eur de couran .

1.8. General assembly instructions

The PIREG-D2 resis ance empera ure con roller is only sui ed for use in a swi ch cabine . Open opera-

ion is no permi ed.

The con roller is designed for ins alla ion in o he swi ch panel and he curren ransformer is fi ed on a 35

mm moun ing rail according o EN 60715 (EN 50022). When ins alling he con roller in he swi ch panel,

here mus be a dis ance of a leas 20 mm from he neighbouring device. Hea dissipa ion from neigh-

bouring devices mus be aken in o accoun (no e he ambien empera ure specifica ions).

1.9. Maintenance

The PIREG-D2 resis ance empera ure con roller does no require any special main enance. However, an

occasional check or igh ening of he connec ion erminals is recommended. Dus deposi s on he con rol-

ler can be removed wi h dry compressed air once he power has been swi ched off.

1.10. Validity

The firs device version (v.vv) shipped was he version 1.00 wi h program versions 1.13 for he display

uni (d.dd), 1.16 for he elec rically isola ed side (g.gg) and 1.10 for he ins rumen a ion side (m.mm).

Supplemen s in his descrip ion which are only valid from a la er version include he version, he no a ion

Vv.vv/d.dd/g.gg/m.mm, e.g. V1.00/1.13/1.16/1.10 from which hey are valid. The device and program

versions are read from he Informa ion menu or by a command (LVERS) via he in erface.

2. Short description

The PIREG-D2 resis ance empera ure-con roller is a empera ure con roller wi h a buil -in sequence con-

rol, which is used o con rol empera ures of hea conduc ors for hea pulse sealing of films and for con-

rolling film sealing machines.

The sealing ransformer is used by he PIREG-D2 on he primary side. The hea conduc or is fed from he

secondary side of he ransformer. The measuring signals are received direc ly a he hea conduc or and

are made available o he con roller.

The PIREG–D2 empera ure con roller has four con rol inpu s and hree relay ou pu s o con rol he film

sealing machine. The PIREG-D2 empera ure con roller can con rol a film sealing machine independen ly

via he la er and he in egra ed sequence con rol. The hree relay ou pu s are divided in o one message

ou pu and wo con rol ou pu s wi h differen capaci ies. In addi ion, here is an alarm ou pu .

The empera ure coefficien of he hea conduc or mus be posi ive. I s resis ance increases when i is

hea ed. This effec is used for empera ure con rol. The empera ure con roller measure and regula es he

resis ance of he hea conduc or. The empera ure coefficien is a ma erial cons an ha depends on he

alloy used for he hea conduc or. The ac ual empera ure is de ermined by measuring he vol age and

curren .

The PIREG-D2 opera es as a propor ional con rol uni ha independen ly de ermines he P-fac or ( he

con rol amplifica ion) for he con rolled par of a process during calibra ion i self. The con rolled sys em

consis s of a sealing ransformer and a hea conduc or. The P-fac or de ec ed during he calibra ion pro-

cess may s ill be correc ed la er by he se ing in he display uni or by a command ( 5.2.5.). Wi h an

addi ional con rol-func ion he ypical offse a propor ional con roller will be minimized (from

V1.00/1.23/1.30/1.25).

The PIREG-D2 is opera ed ei her via he buil -in display uni ( 5.) by five bu ons ( 4.1.) or by he

RS232 or USB in erface which is fi ed o he PIREG-D2. Combina ions of bo h ypes of opera ion are

also possible. An OLED module wi h eigh lines wi h wen y-one digi s each is used as display.

The PIREG-D2 is adjus ed o he hea conduc or's empera ure coefficien s ( 5.7.1.). The PIREG-D2

can also de ermine a hea conduc or’s ac ual empera ure coefficien i self by means of a empera ure

coefficien correc ion ( 5.7.4.). Connec he PIREG-D2 via he RS232 in erface o an ex ernal hermom-

e er exTM, DTM3000 (from V1.00/2.08/1.33/1.26) or previous TM6, which measures he ac ual empera-

ure of he hea ing conduc or o simplify he empera ure coefficien correc ion. Depending on he se ing,

he PIREG-D2 can opera e up o a empera ure range of 500°C.

During calibra ion, he con roller se s i self o he secondary vol age of he ransformer and he curren

hrough he hea conduc or. he secondary vol age of he ransformer may be wi hin a range of 1...80 V.

The curren measured wi h a curren ransformer can range from 20 o 400A. The calibra ion values are

s ored in he PIREG-D2, so ha here is no need for renewed calibra ion and s ar -up ime af er swi ching

on he power, if condi ions have no changed.

The PIREG-D2 can s ore he calibra ion se ings for wo hea conduc ors (from V1.00/1.23/1.30/1.25). A

his wo calibra ions i is necessary o use he same empera ure coefficien s, he same empera ure

range, and he same o her calibra ion se ings ( 3.). For each hea conduc or a separa e empera ure

coefficien correc ion will be de ermined. The ac iva ion of he calibra ion swi ching and he change be-

ween his wo calibra ions will do by command or by con rol inpu s ( 5.6.2).

The PIREG-D2 performs he calibra ion process wi hin a variable room empera ure range of 0-50°C.

During he process, he ac ual reference empera ure mus be se in he con roller's display uni (

5.7.2.). Tha is advan ageous for cons an sealing empera ures wi h differing environmen al condi ions.

High quali y sealing ransformers, such as oroidal core ransformers, are connec ed by he PIREG-D2 on

he primary side, wi hou curren surges occurring. A smoo h swi ching procedure is employed ha com-

pensa es for he remanence of he sealing ransformer. An ini ialising remanence se ing is made au o-

ma ically af er swi ching on he power and following calibra ion,. Only a shor remanence se ing las ing

40 ms for eI core ransformers and 80 ms wi h oroidal core ransformers is needed before each sealing

process. If, wi h oroidal core ransformers, he pause be ween wo sealing processes is longer han 10

minu es, he remanence se ing akes 160 ms. The remanence is he residual magne iza ion in he rans-

former's iron core. During he ini ial remanence se ing procedure, he hea conduc or has o be hea ed

for a shor ime o approx. 40 °C – 70 °C. The PIREG-D2 i self uses a phase angle con roller o regula e

he empera ure.

The PIREG-D2 provides he func ion measuremen pause (from V1.00/1.23/1.30/1.25). A he measure-

men pause he PIREG-D2 s ops he sending of measuremen impulse o he sealing ransformer. There-

fore i is possibly o work a he head conduc or circui wi hou o genera e an error. The measuremen

pause is con rolled by con rol inpu s or by command ( 5.6.2.).

3. Functions

3.1. Control

Wi h he PIREG-D2, here are he following con rol se ings which mus be performed before calibra ion

s ar . The PIREG-D2 peforms he hea conduc or's adap a ion o he vol age Ur and he curren Ir and he

P-fac or (con rol amplifica ion) on i s own.

3.1.1. Heat-up ramp: A hea -up ramp is used o se he ime value in which he con roller increases he

ac ual empera ure value o he arge value wi h a linear ramp ( 5.7.3.). This allows he hea conduc or

o be hea ed gradually.

3.1.2. Setting temperature coefficients: The hea conduc or's empera ure coefficien , which mus be

posi ive, mus be se on he PIREG-D2 ( 5.7.1.). The empera ure coefficien is a ma erial cons an ha

depends on he alloy used for he hea conduc or.

Caution

(EN)

Using hea ing conduc ors wi h oo low a empera ure coefficien , or adjus ing he

con roller o a empera ure coefficien ha is oo high, can resul in uncon rolled overhea ing or

melting of he hea ing conduc or.

Attention (FR): Si un conduc eur de cha

leur es u ilisé avec un pe i coefficien de empéra ure

ou qu’un coefficien de empéra ure rop grand es réglé sur le régula eur, les conduc eurs de

chaleur von chauffer de manière incon rôlée e peuven aller jusqu’à fondre.

The ac ual value canno hen reach he arge value and he con roller con inues o hea up. For hea

conduc ors which have a empera ure coefficien devia ing from he four possible ones, he variable em-

pera ure coefficien se ing mus be used.

3.1.3. Calibration reference time: In he calibra ion process ( 3.2.), he hea conduc or's resis ance is

de ermined a reference empera ure. To ensure ha he reference resis ance value de ermined is cor-

rec , he resis ance of he hea conduc or is measured again af er he calibra ion reference ime has ex-

pired, and compared o he de ermined reference resis ance measured previously. If he difference be-

ween he wo measuremen s is grea er han 1.2%, a new calibra ion process is s ar ed. This preven s

calibra ion from aking place on a hea conduc or which is s ill cooling. The grea er he calibra ion refer-

ence ime selec ed, he sooner resis ance changes in he hea conduc or, caused by cooling during cali-

bra ion, are de ec ed .

3.1.4. Temperature range: The PIREG-D2 offers a choice be ween he four fixed empera ure ranges of

200, 300, 400 and 500°C and a variable empera ure range wi h an adjus men range of 100°C-500°C.

The over empera ure (ra ed value +20%) and under empera ures (-10°C) apply accordingly.

3.1.5. Calibration mode:

- ew calibration: If he calibra ion mode “new-calibra ion“ is chosen, he PIREG-D2 performs a calibra-

ion af er every power-on or he signal “Rese ”. The calibra ion values are no saved. Calibra ion can also

be s ar ed in he Off- or error s a e wi h he signal “Calibra ion S ar ”.

- Save calibration: Calibra ion is only s ar ed wi h he signal “Calibra ion S ar ”. The signal “Calibra ion

S ar ” can be applied in he Off- or error s a e or before power-on. The calibra ion values are s ored in a

non-vola ile memory and canno be dele ed by a power on or he signal “Rese ”. This means ha a new

calibra ion mus be performed af er he hea ing conduc or configura ion was changed or modifica ions

were carried ou on he ransformer. The saved values are hen overwri en wi h he newly de ermined

values.

3.1.6. Transformer type: The PIREG-D2 mus be adap ed o he ype of sealing ransformer, EI or oroi-

dal core. The nex ime he power is swi ched on, he ransformer is charged wi h mul iple unipolar phase

angles and he remanence is aken o a specified posi ion in he ransformer's iron core. The phase an-

gle's curren conduc ion angle for se ing he remanence is adap ed o he ype of ransformer, during he

process. The rapid swi ch-on process is used for every sealing procedure wi h he ransformer being

charged by only a small number of remanence se ing pulses before being swi ched on comple ely. Wi h

oroidal core ransformers, if he pause be ween he wo sealing procedures is longer han 10 minu es,

he number of rapid swi ch-on process pulses is doubled. The sof swi ch-on procedure is used for swi ch-

ing on high-quali y ransformers wi hou power surges occurring.

3.1.7. Reference temperature: The reference empera ure is he environmen al empera ure a which he

hea conduc or resis ance, called reference resis ance (Rref) is de ermined during he calibra ion process.

Wi h he PIREG-D2, he reference empera ure may be se be ween 0 and 50°C.

3.1.8. Temperature coefficient correction: The PIREG-D2 provides wo empera ure coefficien correc-

ions, wi h which sca ering of he hea conduc or ma erials, caused by alloys, can be correc ed.

- Temperature coefficient correction: In normal empera ure coefficien correc ion, he hea conduc or

is hea ed up in eigh empera ure s eps. A each s ep here is a comparison wi h he ac ual hea conduc-

or empera ure and an ac ual value correc ion depending on he devia ion. The normal empera ure coef-

ficien correc ion is par of he calibra ion process ( 3.2.) and also occurs as par of i .

- Single-point temperature coefficient correction: In he case of he single-poin empera ure coeffi-

cien correc ion, correc ion occurs for one opera ing poin . The single-poin empera ure coefficien correc-

ion is carried ou ou side of he calibra ion process and is s ar ed from he Off s a e.

3.2. Calibration

During calibra ion, he PIREG-D2 independen ly adap s o he combina ion of sealing ransformer and

hea conduc or. A he same ime, he vol age Ur a he hea conduc or and he curren Ir hrough he hea

conduc or is measured every second. This s a us is indica ed by he corresponding opera ing s a us sym-

bols in he symbol field of he Working menu on he display uni ( 5.3.). If you make sui able adjus -

men s, a Calibra ion OK message, which is rese during calibra ion, may be issued by he PIREG-D2's

hree relay ou pu s. Addi ional informa ion on he progress of he individual calibra ion s eps is shown by

he ac ual value display or ou pu . The ac ual value is upda ed every second.

The calibration process runs through the following steps:

3.2.1. Initialisation: During he ini ialisa ion s age, he PIREG-D2 iden ifies he da a necessary for cali-

bra ion. In addi ion, i checks he selec ed empera ure coefficien for dynamics and con inui y wi hin he

selec ed empera ure range. Should he dynamics and con inui y exceed he permi ed limi s, he

PIREG-D2 will s op he calibra ion procedure wi h Error 133 (parame er error).

3.2.2. Calibrate input amplifier: The inpu amplifiers for Ur and Ir are adjus ed in s eps o he vol age

and curren a he hea ing conduc or. In he firs s ep, he required modula ion reserve for he sealing

ransformer/hea ing conduc or combina ion is de ermined au oma ically (from V1.00/1.23/1.30/1.25).

In his calibra ion s ep, he ac ual value display shows differen values every second and he ac ual value

ou pu is charged wi h differen vol ages every second. The measured curren or vol age value is dis-

played or issued al erna ely.

Wi h he ac ual value being shown on he display, he curren value is shown in he con roller's 0-50% se

empera ure range and he vol age value is shown in he 50-100% range. The zero poin of he displayed

values is se a 50 %. A he beginning of he calibra ion, he amplifiers (for Ur and Ir) are ini iallised wi h

minimum amplifica ion. A he end of he calibra ion procedure, if he adjus men has been made success-

fully, he range for he displayed curren value is from 16-33% and he range for he measured vol age

value is from 66–83%. The curren value is displayed accordingly in he 0-5V range a he ac ual value

ou pu and he vol age is displayed in he 5-10 V range. The measuremen s' zero poin is around 5V. The

amplifiers (for Ur and Ir) are ini ialised wi h minimum amplifica ion a he s ar of he calibra ion process.

A he end of he calibra ion procedure, if he adjus men has been made successfully, he range for he

displayed curren value is from 1.66 - 3.33 V and he range for he displayed vol age value is from 6.66 -

8.33 V.

3.2.3. Determining the phase shift: During his s ep, he phase shif s be ween Ur and Ir, caused by he

ransformer, are measured and correc ed. The con roller au oma ically se s he op imum scan imes for Ur

and Ir. The ac ual value display and he ac ual value ou pu show he phase shif . A display of approx.

50% of he con roller's se empera ure range or a signal of approx. 5V corresponds o he op imal value.

3.2.4. Determine reference resistance: The reference resis ance of he hea conduc or (Rref) is de er-

mined in his s ep. A reference empera ure of 0-50°C mus be se in he con roller ( 5.7.2.), for he cali-

bra ion process. During calibra ion, he hea conduc or mus be a he reference empera ure o ensure

ha regula ion is exac . By s andardizing he vol age signal (Ur) and he curren signal (Ir), he reference

resis ance for he differen empera ure coefficien s is always wi hin he same resis ance range. If 20 °C

has been selec ed as he reference empera ure, hen hea conduc or's R20 is direc ly de ermined as he

reference resis ance. If a hea conduc or empera ure o her han 20 °C has been selec ed for calibra ion,

hen he de ermined reference resis ance corresponds o he empera ure coefficien s above or below he

value for he R20. The reference resis ance is displayed for one second a calibra ion s age 4 as an ac u-

al value and a he ac ual value ou pu . A a reference empera ure of 20°C, 70%-80% of he se empera-

ure range is displayed as an ac ual value or he ac ual value ou pu vol age amoun s o 7-8V. For he

en ire range of he reference empera ure of 0-50°C he ac ual value display is wi hin a range of 60%-

100% and he vol age a he ac ual value ou pu is wi hin a range of 6-10V.

3.2.5. Temperature comparison time: ( 5.7.3.) The aim of he empera ure reference ime is o ensure

ha he reference resis ance can only be de emined when he hea conduc or has comple ely cooled

down. During he comparison period, he ac ual value display goes down o from 100% o 0% of he con-

roller's se empera ure range. During his reference ime, he signal a he ac ual value ou pu declines

from 10 V o 0 V. Times of 15 or 30 s can be chosen for he empera ure reference ime.

3.2.6. Check reference resistance: Here he reference resis ance is checked af er he empera ure

comparison period has expired. If calibra ion akes place on a hea conduc or ha has cooled down s ill

fur her during he course of he empera ure reference ime, he en ire calibra ion will be discarded and

he procedure au oma ically res ar ed. Once he reference resis ance has been successfully checked

from he se reference empera ure, he empera ure coefficien selec ed and he calcula ed reference

resis ance, he PIREG-D2 calcula es he hea conduc or’s R20 (resis ance a 20°C).

The reference resis ance measured is displayed for one second a he ac ual value ou pu . The same

vol age se a he ac ual value ou pu as when he reference resis ance was de ermined ( 3.2.4).

3.2.7. Determine the P-factor: The P-fac or of he sealing ransformer/hea conduc or combina ion is

de ermined by specific hea ing a a cons an ac ua ing variable. The hea conduc or is ei her warmed by a

maximum of approx. 60 K or charged for a maximum of 120 ne work periods wi h a defined con rol value.

The o al amplifica ion of he con rol sys em is calcula ed from he measuremen of he power fed in o he

hea conduc or and he measuremen of he empera ure increase of he hea conduc or. The P-fac or for

he PIREG-D2 is calcula ed from his.

In he case of highly adverse condi ions in he sealing ransformer and hea conduc or combina ions or

he mains supply, he PIREG-D2’s P-fac or can be correc ed manually wi hin a range of 30…250 % (

5.5.4.).

3.2.8. Set initialising remanence: The sof swi ch-on process is performed by se ing he ini ialising

remanence, in order o connec he sealing ransformer af er calibra ion, wi hou curren surges. The ini-

ialising remanence se ing las s 80 ms wi h EI ransformers and 300 ms wi h oroidal core ransformers

(a a mains frequency of 50Hz).

3.2.9. Temperature-coefficient correction: Tolerances in he empera ure coefficien s can be correc ed

by his fea ure. These resul from he dispersion of he me allurgical composi ion of he hea conduc ors.

In Calibra ion S ep 9, he hea conduc or is hea ed up in eigh empera ure s ages by he PIREG-D2. The

PIREG-D2 hen compares i s ac ual-value empera ure wi h he hea conduc or’s ac ual empera ure,

which is ransmi ed o i as a se value or direc ly as he value of he ex ernal hermome er exTM.

The leng h of he s eps is a resul of he selec ed empera ure range. The firs empera ure s ep is always

50°C. The empera ure of he eigh h empera ure s ep is 20% below he final value of he selec ed em-

pera ure range. The six o her empera ure s eps are equidis an be ween hese. For he 300 °C empera-

ure range, his gives he empera ures 50, 77, 104, 131, 159, 186, 213 and 240°C. For he 500 °C em-

pera ure range, his gives he empera ures 50, 100, 150, 200, 250, 300, 350 and 400°C.

The hea conduc or's ac ual empera ure mus be se as a se value in he display uni or direc ly repor ed

back o he PIREG-D2 as a measuremen by he ex ernal hermome er exTM via he RS232 in erface.

Devia ions of up o ±20 % be ween he calcula ed ac ual value empera ure and he ac ual empera ure of

he hea conduc or can be correc ed ( 5.7.4.). The correc ion process is con rolled by he “S ar ”/”Hea ”

selec ion poin on he Working menu, he “S ar ” sinal or by command. When he TK correc ion hea ing

period is se accordingly, he correc ion process can also run au oma ically.

The hree relay ou pu s of he PIREG-D2 can be programmed o provide a con rol message o open and

close he hea seal jaw bar, while he empera ure-coefficien correc ion is in process. When programmed,

he chosen relay is ac ua ed af er a delay of 250 ms and when he ac ual empera ure has exceeded 95%

of he desired empera ure. The chosen relay is released when he hea seal band's ac ual empera ure is

repor ed back o he PIREG-D2. The nex hea -up s age is approached using he Tc correc ion con rol

message wi h a delay of 250ms o allow he hea seal jaw o open before hea ing. (from

V1.00/1.07/1.29/1.23)

The empera ure coefficien correc ion can be saved, so ha i does no have o be performed again in he

case of a new calibra ion process, bu only when he hea conduc or is changed ( 5.2.5.).

Performing the temperature coefficient correction:

- manual operation: The hea conduc or's ac ual empera ure is repor ed back o he PIREG-D2 as a se

value. There is a swi ch o he nex empera ure hea ing s ep, wi h he rising edge of he “S ar ” signal.

Af er he hea conduc or has reached a uniform empera ure he empera ure se as he se value is aken

over as he ac ual empera ure of he hea conduc or wi h he falling edge of he “S ar ” signal. Opera ion

can also occur wi h he “S ar ”/”Hea ” selec ion poin in he working menu ( 5.2.).

Af er hea ing up o he nex empera ure s age, for he empera ure o be accep ed i is necessary o wai

un il he hea conduc or has ac ually accep ed he new empera ure. The ac ual value display and he

ac ual value ou pu show he PIREG-D2’s corresponding ac ual value empera ure, s ill uncorrec ed.

- manual operation with the external thermometer exTM: The empera ure coefficien correc ion is

also con rolled by he “S ar ” signal resp. he “S ar ”/”Hea ” selec ion poin in he working menu, as de-

scribed above. The hea conduc or's ac ual empera ure is measured wi h he hermome er exTM which is

connec ed o he PIREG-D2’s RS232 in erface. The PIREG-D2 au oma ically ries o es ablish a connec-

ion wi h he hermome er exTM a he beginning of he empera ure coefficien correc ion. As soon as a

connec ion o he hermome er exTM has been es ablished he measured value is displayed ( 5.2.).

If he hermome er DTM3000 is using as ex ernal hermome er exTM, he PIREG-D2 au oma ically se

empera ure uni o he selec ed empera ure uni of he display uni ( 5.8.). Ensure ha he same em-

pera ure uni is se on he TM6 hermome er and on he PIREG-D2 display uni ( 5.8.).

- automatic temperature coefficient correction: The ex ernal hermome er exTM mus be connec ed o

he PIREG-D2 for he au oma ic empera ure coefficien correc ion and he se value for he Tc correc ion

hea ing ime mus be grea er han zero. The hea ing ime is he period un il he hea conduc or has

reached a uniform empera ure a a empera ure s age. The hea ing ime is se in he display uni or by

command ( 5.7.3.). The PIREG-D2 runs hrough he au oma ic empera ure coefficien correc ion on i s

own and remains a each empera ure s age for he prese hea ing ime

Figure 1: Calibration sequence

For each calibra ion, Calibra ion S eps 1 o 8 mus be comple ed by he con roller. S ep 9 is an op ional

calibra ion func ion ( 5.7.4.). If an error occurs during he individual calibra ion s eps, he PIREG-D2

s ops he calibra ion procedure and begins a new a emp . Af er he fif h a emp i abor s he calibra ion

process wi h an error message ( 3.7.).

Af er successful calibra ion, he PIREG-D2 re urns o he Off s a e.

So ha he hea conduc or's R20 reference resis ance is se correc ly, calibra ion mus be performed

when he hea conduc or is a he reference empera ure de ec ed. The ime required for a calibra ion

process is influenced by various fac ors. The vol age level on he hea conduc or, he curren passing

hrough i , he Ur and Ir phase shif and he P-fac or of he sealing ransformer-hea conduc or combina-

ion de ermine he dura ion of calibra ion. The con roller requires a maximum of 46 resp. 60 s for one

calibra ion process. (from V1.00/1.23/1.30/1.25)

If he calibra ion process is no successful, e.g. because he P-fac or has been de ermined incorrec ly, he

con roller makes ano her four a emp s before repor ing an error. In his case, he maximum calibra ion

ime can amoun o 230 resp. 305 s, depending on he empera ure reference ime.

If he calibra ion mode “ ew calibration” is chosen, he con roller always swi ches o calibra ion imme-

dia ely af er a power-on or af er a rese and carries ou a new calibra ion. Calibra ion can also be s ar ed

in he OFF or error s a e wi h he signal “Calibra ion S ar ” or from he Calibra ion selec ion menu of he

display uni .

If he calibra ion mode “Save” is chosen, he con roller swi ches o calibra ion when in an Off- or error

s a e or before power-on only when he “Calibra ion S ar ” signal is applied. Calibra ion can also be s ar -

ed in he Off- or error s a e from he Calibra ion selec ion menu on he display uni ( 5.2.5.). In his ype

of calibra ion, he calibra ion values are saved in a non-vola ile memory and are loaded immedia ely af er

a power-on or he “Rese " signal.

3.2.10. Single-point temperature coefficient correction: Wi h he single-poin empera ure coefficien

correc ion, he hea conduc or’s empera ure coefficien olerances can be correc ed for jus one opera ing

poin . For his opera ing poin he hea conduc or’s ac ual empera ure is repor ed back o he PIREG-D2

as a se value or direc ly as a measuremen of he hermome er exTM. The single-poin empera ure coef-

ficien correc ion is carried ou ou side he s andard calibra ion and is s ar ed from he Off-s a e. The sin-

gle-poin empera ure coefficien correc ion has one Off- and one On-s a e. Af er he single-poin empera-

ure coefficien correc ion has been s ar ed, he PIREG-D2 is in he Off s a e. When he PIREG-D2 is in

he On-s a e, he hea ing conduc or is hea ed o he empera ure which was se as he se value in he

Off-s a e. Af er hea ing he empera ure is only accep ed when he hea ing conduc or has defini ely

reached he empera ure. The ac ual value display or he ac ual value ou pu show he PIREG-D2’s ac ual

value empera ure, s ill uncorrec ed. The single-poin empera ure coefficien correc ion is ended upon

exi ing he On-s a e. The correc ion process is con rolled by he “S ar ”/”Hea ” selec ion poin in he work-

ing menu, he “S ar ” single or by command. When he TK correc ion hea ing period is se accordingly, he

one-poin empera ure coefficien correc ion process can also run au oma ically.

Devia ions of up o ±20 % be ween he calcula ed ac ual value empera ure and he ac ual empera ure of

he hea ing conduc or can be correc ed. The single-poin empera ure coefficien correc ion can only be

performed if he normal empera ure coefficien correc ion covering eigh poin s ( 3.2.9.) has no been

carried ou during calibra ion. The single-poin empera ure coefficien correc ion is rese a each calibra-

ion.

The empera ure coefficien correc ion can be saved, so ha i does no have o be performed again in he

case of a new calibra ion process, bu only when he hea conduc or is changed ( 5.2.5.)

Performing the single-point temperature coefficient correction:

- manual operation: Single-poin empera ure coefficien correc ion is s ar ed from he Calibra ion selec-

ion menu on he display uni ( 5.2.5.) of he PIREG-D2 or by command when he PIREG-D2 is in he

Off-s a e. The PIREG-D2 re ains he empera ure se as arge value as he empera ure of he opera ing

poin as long as a low-signal is applied as “S ar ” signal. When a high-signal is applied as “S ar ” signal

Ac . val.

display

100 %

1.66

3.33

6.66

Ac . val.

ou pu

8.33

10 V 1. Ini . 2. Calibra e

inpu amplifier

3. De ermine

phase shif

Calibra ion-

reference ime

4. De ermine reference resis ance

5. Calibra ion-

reference ime

6. Check reference resis ance

7. De ermine

P-fac or

S ar

Signal

8. Ini ialising remanence-se ing

1 2

50°C

9. Tempera ure coefficien correc ion

43 5 6 7 8

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