Impulse Heat Seal Machine Transformers, Boosters, and Line Filters
In TOSS impulse heat sealing systems, power transformers, current transformers, and line filters are essential for ensuring optimal performance and reliability. Power transformers step down the incoming high-voltage power to a lower, manageable voltage suitable for the heating elements and control electronics, ensuring efficient and safe operation.
Current transformers measure and monitor the electrical current flowing through the heating elements, offering real-time feedback for precise temperature control and enabling dynamic power adjustments. Line filters remove electrical noise and interference from the power supply, providing clean and stable power crucial for maintaining consistent heat levels during the rapid heating and cooling cycles of the impulse process. Together with the PIREG® heat seal controller and TOSS Alloy-20® heatseal bands, these components ensure the system delivers consistent and reliable seals by maintaining the required voltage and current stability.
TOSS Impulse Heat Seal Power Transformers
TOSS heatseal power transformers are designed and built to mate with PIREG® impulse heat seal temperature controllers. It is important to use a properly designed transformer because the performance of the sealing system depends upon the correct selection and use of each component in the system. The Secondary Voltage selected will affect the rate of heatseal band temperature rise from the moment of impulse until reaching the selected set point temperature. This rate of rise should not exceed 1˚C/mSec.
Click for larger 360 view of the TOSS 0.5 KVA Impulse Heat Seal Power Transformer shown.
For More Information see 9 Steps to Heat Sealing Perfection: Step 8 - Transformer Selection
Voltage Selection
TOSS power transformers are supplied with terminal blocks or 24-inch lead wires to facilitate installation. Each terminal or lead is identified as follows:
Input Side:
H1, H2, H3, H4 are the Primary connections
Output Side:
X- Secondary Voltage Common
1- Lowest Secondary Tap
2- Medium Secondary Tap
3- Highest Secondary Tap
Additional Voltage Selections
Additional voltage selections may be obtained by connecting at any two of the Secondary connections (#1,2, or 3).
EXAMPLE: If the transformer is specified as 220/12,30,36 you will get 12V, 30V, or 36V by connecting across "X" and “1”, “2”, or “3” respectively. However, you can also get 24V by connecting at “1” and “3” (36-12= 24). Similarly, the transformer specified above can be used for 12V, 18V, 24V, 30V, or 36V.
CAUTION: It is not recommended to configure a secondary voltage that is lower than the lowest voltage tap on the transformer. (On a 12,16,20 transformer, do not try to achieve 8 Volts by going between 20 & 12)
NOTE: Only two of the Secondary leads can be used at any one time. The others must be capped off.
Start-Up
Inspect the wiring to be sure that all connections to the transformer, the heatseal jaw and the controller are all very tight. Loose connections will cause erratic results.
Connect the transformer using the appropriate secondary voltage selection and try the system. The response of the controller may be slow. If so, set-up the voltage until the response is fast enough to produce the desired result.
CAUTION: Take care not to exceed the 1˚C /mSec limit.
Grounding the Transformer
To properly ground the transformer the following instructions can be used: Remove one of the bottom screws connecting the mounting brackets and the laminations. Remove and discard (2) nylon shoulder washers. Obtain a Grounding Wire (Green #12AWG stranded wire with #10 Ring terminal crimped on both ends). Place a #10 washer on the screw, place the ring terminal on the screw, and then replace the bracket using screw and nut to hold the assembly tight together.
When the transformer is installed the grounding wire must be firmly attached to the machine frame or other electrical ground.
Choosing the Correct Transformer
We recommend that you always contact our Applications Engineers to determine the correct size for your transformer. Factors that are taken into consideration are the size of your heat seal band, number and types of bands being heated, cycle timing, desired heat-up times, & incoming house voltage.
Current Transformers
The current transformer continuously monitors the current passing through the heat seal band. This, together with voltage monitoring, allows the controller to accelerate heating without overshooting and finally monitors the cooling to determine the optimum moment to open the seal jaws and release the workpiece.
The current transformer supplied with the PIREG temperature controllers is an integral part of the control system.
The current transformer may only be operated if it is connected to the temperature controller correctly.
TOSS Power Boosters
TOSS Technology can be supplemented with TOSS power boosters to accommodate the high power needs of extra large heat seal bands or systems. Using a power booster, multiple bands may be connected in series or parallel to be driven by a single controller. Systems can be designed for power supplies of 115, 230, 400, or 480 VAC.
TOSS boosters can be used as external switching amplifiers in addition to the temperature controller. They allow a higher current to be present on the primary side of the current transformer.
TOSS PERIG Temperature Controller Line Filters
In order to comply with EMC directives and ensure CE conformity, all TOSS PIREG impulse heat seal temperature controllers require a line filter.
A TOSS line filter is placed between the AC input and the TOSS PIREG controller to attenuate conducted radio frequencies radio frequency interference (RFI), also known as electromagnetic interference (EMI) to protect the temperature controller against line disturbances.
Functions of the TOSS Line Filter
- Suppresses electromagnetic interference signals transmitted through conduction
- Attenuate unwanted current passing through cables or wires, allowing desirable currents to pass through
- Prevent electronic control circuit from having peak voltage on the mains input that can be produced by electromechanical switches
- Act in opposite directions to attenuate interference variables so an acceptable level of interference can be achieved
- Suppress noise from grid power
NOTE: If your application needs to meet European CE ratings, a TOSS line filter will be required.