PILLAR TECHNOLOGIES
OPERATOR S MANUAL
INDUCTION CAP SEALING SYSTEMS
2 kW Unifoiler Series
Waterless System
PP1239-27
Model # _______________
Serial # ________________
PILLAR TECHNOLOGIES
A Division of Illinois Tool Works, Inc.
475 Industrial Drive
P.O. Box 110
Hartland, WI 53029
TU
Phone: (262) 912-7200
Toll Free: (888) PILLAR-6 (888) 745-5276
Fax: (262) 912-7272
www.pillartech.com or sales@pillartech.com
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TU
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and
TU
PO Box 584
Banbury
Oxon, OX16 6BW, UK
Phone: +44 (0)1869 338100
www.pillartech.co.uk or induction@pillartech.com
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TU
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EDIT HISTORY
Printed on 24 Oct 07
Edit History:
November 5, 1999
January 12, 2000
March 13, 2000
July 24, 2000
December 19, 2000
May 17, 2001
July 12, 2001
January 29, 2002
July 19, 2002
November 13, 2002
June 4, 2003
June 9, 2003
March 4, 2004
October 12, 2004
October 28, 2004
January 4, 2005
January 26, 2005
October 19, 2005
June 13, 2006
-
First publication
Revised text on page 31
Auto Start option clarification; general updates
Added encoder mounting instructions
Updated schematic
Added environmental conditions
Added CE, ETL Declaration
Added Stacklight Option Description
Revised entrance / exit reject wording
Revised reject setup
Updated loose cap features
General Updates
Updated portable stands and options
Added reject verification
Added Auto Start indication
Update spares kits (EC #09661)
Added alarm silence instructions
Added SUNX amplifier
Updated to new detection system
Confidentiality:
This manual and any documents associated with this manual are the proprietary property of Pillar
Technologies. These documents are for use by those having a direct business relationship with Pillar
Technologies only and are not to be disclosed to third parties. Unauthorized disclosure can lead to
legal recourse.
Patents:
Equipment manufactured by Pillar Technologies may be covered by one or more U.S. patents.
Other patents pending.
Copyright:
©1999, Pillar Technologies. All rights reserved. This manual may not be reproduced in whole or in
part by any means without written permission of Pillar Technologies, 475 Industrial Drive, Hartland,
Wisconsin 53029, U.S.A
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TABLE OF CONTENTS
Declaration of Conformity
Type IIA
Manufacturers Name:
Pillar Technologies
Manufacturer Address:
475 Industrial Drive
Hartland, WI 53029
USA
Product Name:
Induction Capsealer
Model Number:
2kW UniFoiler
The Pillar Induction Capsealing System, model 2kW UniFoiler, in addition to one or a
combination of induction sealing coils and all related optional equipment has been tested to the
Machinery Directive 98/37/EC and the Electromagnetic Compatibility Directive 89/336/EEC
and conforms to the following standards:
Electromagnetic Emissions:
EN 55011: 1998, Class A
Electromagnetic Immunity:
EN 50882-1: 1997
European Low Voltage Directive:
Safety in Electroheat Installations - Part 1:
General Requirements
EN 60519-1: 1993
IEC 519-1: 1984
Safety in Electroheat Installations Part 3:
Particular Requirements for Induction and
Conduction Heating and Induction Melting
installations
IEC 519-3: 1988
This equipment is also certified by Intertek Testing Services, 7250 Hudson Blvd., Suite 100,
Oakdale, MN 55128 to be compliant with the following Safety Standards, and may bear the ETL
Mark to certify as such:
UL1012, Standard for Power Units Other Than Class 2
CAN/CSA C22.2 No. 107-1, Commercial and Industrial Power Supplies
Models: 2kW UniFoiler
Richard J. Washebeck
Richard J. Washebeck, Director of Engineering
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TABLE OF CONTENTS
TABLE OF CONTENTS
Introduction .............................................................................................................................................1
About This Manual ......................................................................................................................1
Some Terms..................................................................................................................................1
Product Description......................................................................................................................2
Safety ........................................................................................................................................................3
Equipment Safety Features ..........................................................................................................3
Precautions ...................................................................................................................................3
Installation ...............................................................................................................................................5
Unpacking ....................................................................................................................................5
Stationary Coil Support................................................................................................................5
Unitized Stand ..............................................................................................................................7
Inverter..........................................................................................................................................9
Sealing Coil ................................................................................................................................12
Optional Equipment ...................................................................................................................13
Wiring .........................................................................................................................................13
Setup .......................................................................................................................................................15
Universal Coil ............................................................................................................................15
Channel Coil ...............................................................................................................................17
Transformer Tap Changes .........................................................................................................18
Before Starting ...........................................................................................................................19
Operation ...............................................................................................................................................20
Inverter........................................................................................................................................20
Diagnostic Lights .......................................................................................................................20
Operator Controls .......................................................................................................................22
Power Setting .............................................................................................................................23
Optional Equipment .............................................................................................................................25
Stack Light .................................................................................................................................25
Bottle and Cap Detection System ..............................................................................................26
Stalled Bottle Detector ..................................................................................................26
Specifications ....................................................................................................26
Features .............................................................................................................27
Function ............................................................................................................27
Missing Foil Detector ....................................................................................................27
Features .............................................................................................................28
Function ............................................................................................................28
Loose Cap Detector .......................................................................................................28
Features .............................................................................................................29
Function ............................................................................................................29
Setup and Operation ......................................................................................................30
Pneumatic Reject........................................................................................................................34
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TABLE OF CONTENTS
Setup and Operation ......................................................................................................34
Reject Control Setup .....................................................................................................34
In-feed Bottle Stop .....................................................................................................................36
Tap Selector Switch ...................................................................................................................37
IQ/OQ Documentation...............................................................................................................38
Conveyor System .......................................................................................................................39
Service.....................................................................................................................................................41
Inverter........................................................................................................................................41
Inspection.......................................................................................................................41
Troubleshooting.............................................................................................................41
Coil Support ...............................................................................................................................42
Sealing Coil ................................................................................................................................42
Specifications .............................................................................................................................43
Spare Parts ..................................................................................................................................44
Dimensions .................................................................................................................................45
LIST OF FIGURES
Figure 1 Stationary Conveyor Mounted Coil Support ........................................................................6
Figure 2 Typical Unitized System Components ..................................................................................7
Figure 3 Checking that the coil is level................................................................................................8
Figure 4 Typical Inverter Cabinet ......................................................................................................10
Figure 5 Input Power Connection (BE3453-33)................................................................................11
Figure 6 Adjusting the universal coil .................................................................................................16
Figure 7 Channel Coil.........................................................................................................................17
Figure 8 Operator Panel ......................................................................................................................20
Figure 9 Optional Stack Light ............................................................................................................25
Figure 10 Encoder Mounting .............................................................................................................32
Figure 11 Typical Bottle and Cap Detection System with Reject & In-Feed Bottle Stop...............33
Figure 12 Conveyor Sprocket Diameter ............................................................................................35
Figure 13 Setting Container Spacing .................................................................................................36
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TABLE OF CONTENTS
Figure 14 Tap Selector Switch ...........................................................................................................38
Figure 15 Conveyor System ...............................................................................................................40
Figure 16 Outline Drawing 2 kW-C ..................................................................................................45
Figure 17 Outline Drawing 2 kW-U ..................................................................................................46
Figure 18 Outline Drawing 2 kW-UC ...............................................................................................47
Figure 19 External components..........................................................................................................48
Figure 20 Internal components ...........................................................................................................49
Figure 21 24 - Electrical Schematics (ETL) ................................................................................ 50-53
Figure 25 26 - Electrical Schematics (CE) .................................................................................. 54-57
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vii
INTRODUCTION
2 kW Unifoiler
Induction Cap sealing System
Introduction
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About This Manual
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This manual contains information for installation, operation, maintenance and repair. It should
be read by installers, operators, maintenance personnel, and other personnel who may come in
contact with this equipment.
This manual covers the Unifoiler series of cap sealing systems. All of these systems incorporate
an inverter, and a sealing coil as standard equipment. Other options are available, such as a
unitized stand on wheels, or a missing foil / stalled bottle detection system. Some references in
the manual may not reflect your particular equipment configuration but each component of your
system will be explained individually.
If you have any questions regarding the installation or use of the product, you may contact a
Pillar Technologies representative for advice. You may also contact the Service Department
directly during normal working hours between 8:00 a.m. and 5:00 p.m. CDT. In case of an
emergency, a 24-hour a day, seven-day a week service hotline is available. Your message will
be forwarded to a service representative who will then return your call.
Some Terms
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Some terms used throughout this manual:
Optical sensor - This refers to the type of device that is used to detect the presence of an object
within the beam of light. The sensors used in your system are through-beam. It consists of two
sensors in alignment with one another across the conveyor that the containers pass between.
Capacitor bank - The capacitors are located within the enclosure on the top of the sealing coil.
These work together with the sealing coil to generate the high-energy electromagnetic field.
Locating the capacitors at the coil eliminates the need for heavy, water-cooled leads to the coil.
IGBT - Insulated Gate Bipolar Transistor. A very rugged type of transistor that can accommodate
high power.
Impedance - An electrical value associated with ability of the inverter to match the sealing coil's
electrical characteristics and power requirements. This value changes in response to the amount of
1
INTRODUCTION
metal passing through the sealing coil's electromagnetic field.
Inductive sensor - This is a type of electronic sensor that detects the presence of metallic objects
when passed near it, such as a foil liner.
Induction - The phenomenon where electrical energy is transferred from one device to another
through the air by an electromagnetic field.
Inverter - This is the electrical unit that supplies high voltage, high frequency energy to the sealing
coil.
Transformer tap - The inverter contains a transformer that couples it with the sealing coil.
Different size bottle caps will load the sealing coil differently. A voltage tap connection on the
transformer is changed to permit the proper coupling of energy between the inverter and the foil
liner.
Universal coil - A special sealing coil available exclusively from Pillar that permits sealing of a
wide range of cap sizes without changing coil sizes. It works by angling the coil with respect to the
conveyor path. Whatever the cap size, the entire cap will pass through the electromagnetic field.
Channel coil - A coil design which is directed toward the various child resistant and dispenser type
caps which would be very difficult to seal using a convention flat coil system. The sealing coil
allows for the container neck and cap to pass through the electromagnetic field inside the tunnel,
providing uniform heating and sealing to the container.
Product Description
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An induction cap sealing system is used to apply a hermetic seal over the mouth of a jar or bottle.
These seals can provide evidence of tampering, preserve freshness, prevent pilferage, and provide
leakage protection during handling or shipping.
A special plastic cap containing an aluminum foil disk is used. After the cap is screwed onto the
bottle, it is passed beneath an induction sealing coil. This coil radiates an electromagnetic field,
which causes the aluminum disk to heat up. A coating laminated to this disk softens and is fused to
the mouth of the bottle.
Features:
The inverter circuitry employs IGBT technology. The IGBT is a rugged, state-of-the-art
transistor device now being used in critical, high power circuitry for military and commercial
aircraft.
The inverter is forced-air cooled and operates quietly and reliably without the need for expensive
and high maintenance water cooling systems.
2
INTRODUCTION
The cap sealer utilizes a stainless steel enclosure with corrosion resistant components and
hardware.
The inverter cabinet is designed for ease of installation on most conveyor styles. With the
unitized system, the entire system is located at the conveyor where the operator can easily view
the controls and make necessary adjustments.
The locally mounted operator panel puts all the operator functions right at the point of operation.
A standardized coil mounting system accepts any Pillar sealing coil.
Several styles of sealing coils are available to adapt to a variety of sealing needs. The coils are
easy to mount, simple to adjust, and can be quickly removed for fast and efficient coil exchange.
Safety
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Equipment Safety Features
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Any moving parts could cause injury if a person comes in contact with them. The containers
moving through the equipment are no exception and caution should be used when working
around the equipment during operation.
For your safety, you should never bypass the interlocks or guarding system while the equipment
is operating.
Precautions
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Pillar Technologies makes every effort to build equipment that is safe and as free of hazards as
technically possible. However, not all hazards can be totally eliminated by design. It is
therefore imperative that all personnel who will use or service the equipment become familiar
with this manual. Areas in this manual concerning safe operation are identified with the
following symbols.
CAUTION
The cap sealing system creates an electromagnetic field that will cause heating in metal
objects brought into proximity of the sealing coil. It is recommended that rings, watches,
bracelets, or other jewelry not be worn when working near the coil. Serious injury could
result if these items are worn near the coil.
3
INTRODUCTION
The cap sealing system is not designed to be located in a wash down, wet, or hazardous
environment.
The customer must ensure that all applicable safety code requirements are complied with
when installing this equipment.
Input power must always be disconnected and locked out at the source before service or
setup of the equipment.
All guards, shields, and barriers must be in place before starting the equipment.
Do not operate, troubleshoot, or maintain the cap sealing equipment while under the
influence of any type of drug or alcohol.
Proper maintenance of the equipment, including periodic inspection , is necessary to
maintain the highest degree of safety.
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Always observe all safety warnings and notices on the equipment and in this manual.
4
INSTALLATION
Installation
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Unpacking
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Your Pillar cap sealer has been completely tested, inspected, and carefully packaged prior to
shipment. Please remove the packing materials carefully and watch for any visual signs that the
equipment may be damaged. Also ensure that all packing material is carefully inspected for
components which may be hidden within them. If upon arrival you find that the equipment has
been damaged in route, please do the following:
Retain all packing materials in which the equipment was originally shipped for possible
inspection by the carrier.
Notify the carrier immediately upon confirmation of the damage and file the appropriate claim.
Notify Pillar Technologies as soon as possible for instructions regarding the damaged
equipment.
NOTE: Failure to contact the carrier prior to installation of the equipment or disposal of the
packing materials may result in loss of claim from the carrier.
Stationary Coil Support
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The coil support is to be mounted at the spot on the conveyor system where the sealing is to take
place. Normally, this is directly after the capper, where the bottles will still be spaced apart.
Figure 1 shows the components of the coil support assembly.
Generally, the support's mounting plate can be attached directly to the side of the conveyor.
However, it may be necessary to fabricate a plate or bracket to adapt to a particular conveyor. A
bracket could be made to mount from the floor, if desired. In any case, the installation must be rigid.
If the coil support is mounted directly to the conveyor, bracing of the conveyor may be necessary to
provide sufficient rigidity.
When planning the location of the mounting plate, note that the range dimensions in Figure 1 are
given from the bottom of the attachment plate, not the bottom of the coil. The thickness of the coil
depends on the particular style used. Consider also the range of bottle sizes that are intended to run
under the coil.
5
INSTALLATION
3.12" [79.38] MIN
7.62" [193.55] MAX
Figure 1
6
Stationary Conveyor Mounted Coil Support
INSTALLATION
Unitized Stand
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To minimize the installation and setup time required, an optional unitized system is available
which combines the inverter cabinet, coil support, and sealing coil onto a common frame with
casters for easy movement from location to location.
A typical unitized system is shown in Figure 2. The basic components include the inverter cabinet
and the adjustable coil support stand. The leveling feet should be lowered to the floor, preventing
tipping, and stabilizing the installation.
CAUTION
POWER SUPPLY STAND
MUS T BE LOWERED BEFORE
MOVING MACHINE
Figure 2 Typical Unitized System Components
7
INSTALLATION
POWER SUPPLY STAND
MUST BE LOWERED BEFORE
MOVING MACHINE
Regardless of the type of coil support provided, the system must be mounted level so that the coil
will lie parallel to the conveyor's surface. It is important that the gap between the top of the bottle
cap and the bottom of the coil remain constant as the bottle passes underneath. Verify this by
mounting a coil and measuring the distance from each end down to the conveyor track or belt as
shown in Figure 3. On narrow conveyors, it may be necessary to space the coil support mounting
plate further away from the rear side of the conveyor.
Figure 3 - Checking that the coil is level
8
INSTALLATION
Inverter
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The inverter enclosure is not designed to be located in a wash-down, wet,
or hazardous environment!
The inverter is air-cooled and contains a fan to force air through the enclosure. A minimum of six
inches of clearance should be provided on both the sides and rear of the enclosure to ensure adequate
airflow.
The 208 or 240 VAC (single phase) input power enters at the rear of the cabinet and a safety
disconnect is provided with lockout capability. A cord grip has been provided to accommodate a
power cable. If another type of fitting is needed, some modifications to the cabinet may be
necessary. The customer must provide the necessary circuit protection (fusing or circuit
breakers) in accordance with applicable codes and practices. The systems are wired for 240 VAC
power when they leave the factory. Full specifications are listed on page 43. Refer to the wiring
diagram BE3453-33 on page 11 for power input terminals connections. Never connect input
power to disconnect terminals (1) and (3) simultaneously. Damage will occur to the inverter.
Also see the wiring diagrams at the end of this manual for control transformer tap changes for your
supply voltage. The sealing coil connection is provided at the rear of the cabinet and can be
easily removed for fast coil change over or maintenance. Figure 4 shows a typical inverter
arrangement.
It is the customer s responsibility to ensure that all applicable safety
code requirements are complied with when installing this equipment.
Cables to the coil should be routed back to the inverter along the coil support to prevent cables from
obstructing container flow.
9
INSTALLATION
Provisions have been made to allow customer alarm or interlock circuitry to be wired into the
inverter. Details on using these interlocks may be found on page 14. If optional equipment has been
provided, or if special features have been incorporated into your equipment, please refer to the
specific wiring diagram for that option or feature.
A unitized adjustable stand is also available to reduce installation time and is described in more
detail on page 7. If the system was shipped as a stand-alone cabinet, it can be located in any
convenient location that provides adequate ventilation for cooling.
Figure 4 - Typical Inverter Cabinet
10
INSTALLATION
11
INSTALLATION
Sealing Coil
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Coil failures due to overheating can result in personal injury. Please
ensure that all safety interlocks and protection devices are connected
and functioning properly.
There may be several different styles of sealing coils available that can adapt to various applications.
The method of mounting is the same for all styles of conveyor coils. All coils styles consist of an
inductive winding, a load capacitor, and a housing to hold these components.
Always disconnect the supply power from the cap sealer before
mounting or removing sealing coils
To mount the conveyor coil, rotate the clamp lever counterclockwise until it is loose enough to slide
onto the support. A spring will force the flanges apart to provide clearance for mounting. The screw
mechanism has a stop that prevents the handle from coming off. Note: Do not rotate the clamp lever
past the stop position.
Lift the coil up to the attachment plate and slide it into the slot. Rotate the lever clockwise and
tighten until the coil is secure. Final alignment of the coil is discussed in the Setup section,
starting on page 15. Connect the power cable from the coil to the back of the inverter cabinet. It
is important that this connector be properly positioned and securely fastened.
12
INSTALLATION
Due to the sealing coil weight, it is recommended that the installation be
performed by two people, or with the assistance of a mechanical aid.
Optional Equipment
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Optional equipment may have been purchased at the time of original purchase. If this is the case,
the optional equipment will be installed on the Unifoiler system as much as possible. For more
information on specific options, please see the Optional Equipment section of this manual.
Wiring
Besides power input and interlocking, there are several other terminals available for optional
equipment and special features when provided. The system schematic diagrams appear on pages 5057. Please refer to these documents when installing your cap sealing system, and if you have any
questions regarding your installation, contact the Pillar Service department.
AC input - The supply voltage is connected to the disconnect switch provided at the rear of the
inverter cabinet. Line fuses are provided at the main terminals to protect the inverter components.
The system can be connected for 208 or 240 VAC +/- 10%, single phase. Refer to drawing
BE3453-33 on page 11 for the connection diagram. Also see the system schematic diagram at the
end of this manual for further information.
Auto-start - A contact closure across terminals [77] and [93] will enable the auto-start feature. This
feature could be used to put the cap sealing system into a standby mode when the conveyor system
stops. When the conveyor starts again, the cap sealing system will resume operation automatically.
When the contacts are closed, the cap sealing system will be in a ready condition. Initially, the
START button is pressed and the unit runs. If the contacts are opened, the cap sealing system will
stop delivering power to the sealing coil, but will remain in a ready state. When the contacts are
closed again, operation will resume, if no fault condition exists.
If the safety interlocks or external customer interlocks are opened, the cap sealing system will shut
down completely. To resume operation, the interlocks must be satisfied, the auto-start contacts
closed and the START button pressed.
If this feature is not used, a jumper must be installed across these terminals.
13
INSTALLATION
Note: Jumper J3 on the main control circuit board will inhibit this feature. If the auto-start function
is to be used, this jumper must be removed.
Note: When the stalled bottle feature is enabled, the operator needs to restart the inverter at the main
operator panel prior to resuming operation.
Customer interlock - Terminals [89] and [90] are provided for the customer interlock, and can be
used to stop the cap sealing system. For the unit to run, a maintained contact closure is required
across these terminals. When the contacts open, the unit will stop. Once the contacts are closed
again, the START button must be pressed to resume operation. If this functionality is not required, a
jumper must be placed between these terminals.
Low output alarm (LSI) - This alarm activates the user alarm indicator and alarm relay, which
changes state, to signal a loss of seal condition. Both normally open and normally closed contacts
are available at terminals [94], [95], and [96]. (See pages 50-57)
Use these terminals to activate an alarm or to shut down the conveyor system when the cap sealing
system is not delivering sufficient output compared to the alarm set point. When the set point for
this alarm is adjusted to zero, the relay contacts will not change state, even if the output of the power
supply is zero.
Run mode monitor - Whenever the cap sealing system is running, the run relay will be energized.
Both normally open and normally closed contacts are available at terminals [97], [98], and [99].
(See pages 50-57)
Use these terminals to monitor the operational mode of the cap sealing system.
Temperature switch interlock - This interlock is used to monitor the operation of the coil cooling
system (fan), and is internally connected to the inverter whenever the coil cable is connected.
14
SETUP
Setup
There are different procedures for setting up coils, depending on the style, but for all types of
coils it is important that the conveyor guide rails are adjusted properly to allow bottles to pass
without restriction.
Containers must pass under the sealing coil unimpeded and with
adequate speed to prevent overheating. Containers that pass to slow or
stall may overheat and possibly catch fire.
Depending on the size of bottle cap, a limit may occur in the inverter, preventing full output power
from being obtained. This condition occurs when the load on the inverter is higher than it can
deliver. If the power meter reading on the front panel of the power supply decreases when there are
bottles under the coil, change the output transformer tap. Please see the discussion on changing
transformer taps at the end of this section.
Universal Coil
The universal coil can adapt to a very wide range of cap sizes and shapes which allows the same coil
to be used for a number of different applications. This is accomplished with a special coil design
that allows you to angle the coil along the path of the conveyor. To achieve the best performance
from this coil, follow the setup instructions below.
Due to the sealing coil weight, it is recommended that the installation be
performed by two people, or with the assistance of a mechanical aid.
1. Place a bottle with a cap under the coil. Adjust the vertical crank until there is about 1/8" (3
15
SETUP
mm) clearance between the bottom of the coil and the top of the cap. Slide the bottle from one
end of the coil to the other to check the clearance. It is important that the same spacing be
achieved from one end of the coil to the other. This clearance must be enough to ensure that a
bottle with a loose or crooked cap will not jam under the coil.
2. Loosen the coil mounting clamp lever.
3. Note the centerline marks on each end of the coil. Slide and swivel the coil so that the mark on
the entrance end of the coil is positioned ¼ outside of one edge of the bottle cap. The mark on
the exit end of the coil is to be positioned ¼ outside of the opposite edge of the bottle cap. In
other words, the centerline of the coil is to sweep across the full width of the bottle cap. See
Figure 6 below for additional adjustment instructions. It is best to angle the capacitor bank side
of the coil over the conveyor.
4. Firmly tighten the coil mounting clamp lever. Make sure that the coil does not swivel during
tightening.
Figure 6 - Adjusting the Universal Coil
16
SETUP
Channel Coil
The channel coil is intended for specialty caps such as those with spouts. Channel coils are designed
to fit a specific cap diameter and height. Verify that the coil to be mounted is appropriate for the
type of cap to be sealed.
Figure 7 Channel Coil
1. Note the horizontal scribe marks on each end of the coil. These show the location of the sealing
field. Adjust the vertical crank until these markings are even with the lip of the bottle where the
foil seals.
2. Loosen the coil mounting clamp lever.
3. Slide and swivel the coil so that the bottle can pass underneath from one end to the other without
17
SETUP
the cap rubbing the sides of the channel.
4. Firmly tighten the coil-mounting clamp. Make sure that the coil does not swivel during
tightening.
Transformer Tap Changes
Always disconnect the supply power from the cap sealer before
removing the enclosure cover.
Never attempt to change transformer taps with power applied.
If the bottling line is capable of a variety of bottles and caps, it may be necessary to change the
output transformer tap to achieve maximum sealing performance. Different size bottle caps will
load the inverter differently and may cause a mismatch between the inverter and the sealing coil.
The output transformer taps are provided to compensate for this condition.
The power output terminal strip located on top of the output transformer contains several terminals
corresponding to different taps of the transformer. Refer to the wiring diagram on pages 50-57 when
changing transformer taps.
One output wire from the sealing coil must be connected to the H1 terminal. The other wire can be
attached to terminal H2, H3 or H4. Tap 1 (H2) is the lowest voltage; tap 3 (H4) is the highest
voltage.
If the impedance low indicator lights, try changing to a lower voltage tap. If small caps do not seal
well, try changing to a higher voltage tap. For best results, use the highest voltage tap that does not
cause the impedance low indicator to light.
If the highest voltage tap does not produce adequate sealing, the conveyor speed must be reduced to
allow the cap to remain under the coil for a longer time.
18
SETUP
Before Starting
Do not wear jewelry such as watches, rings, or bracelets while working
near the sealing coil. Metal objects can become extremely hot if brought
into close proximity of the sealing coil when power is applied.
Always keep hands clear from under the coil unless you are certain that
the inverter is shut off.
1. Check to be sure that the coil has been mounted and aligned as described above.
2. Check to see that the power cable connected between the coil and the inverter is properly seated
and securely tightened.
3. Make certain that all enclosure doors are properly closed and that all internal and external
interlocks are closed.
19
OPERATION
Operation
Inverter
A disconnect switch is located on the rear of the cabinet. This switch removes all power from the
inverter cabinet. A circuit breaker, which is also located on the rear of the cabinet, protects the
internal circuitry from damage. The circuit breaker also supplies power to inverter components and
options.
READOUT SELECTION
POWER
SET POINT
ALARM/TIMER
SET POINT
RUN
SETUP
DURATION
RESET
START
STOP
DELAY
Figure 8 - Operator Panel
The operator panel shown in Figure 8 above contains the diagnostic indicators, status indicators,
operating set points, and a digital meter, which indicates output power. Refer to the troubleshooting
section starting on page 41 for advice on how to interpret the different lights. A brief description of
their function will be given here.
Diagnostic Lights
Setup - Indicates that the system is in the set up mode for the bottle and cap detection option.
Refer to the section on detection systems for further details.
Inverter On - Indicates that power is being supplied to the sealing coil. When indicator is
flashing, this means that the auto start contact is open and that the inverter is in standby mode
and ready to turn on when the auto start contact closes.
Alarm Fault - Lights when the coil output has dropped below the threshold set by the alarm set
point on the panel. This is used to indicate that the inverter is not supplying the desired power to
the coil. In such a case, proper sealing may not be accomplished. This light shows that the
alarm circuitry is active.
20
OPERATION
Impedance High - If this light should illuminate when the inverter is in Stop mode, it does not
indicate a problem. If it illuminates while the inverter is running, there may be a problem inside
the inverter or coil. Typically this indicates that a capacitor within the coil assembly has opened
up. In this event, please contact Pillar Service.
Impedance Low - Indicates that an impedance mismatch has occurred. This condition occurs
when the load on the inverter is higher than it can deliver. When this occurs, the output
transformer tap may need to be changed to deliver a lower voltage to the sealing coil. Refer to
page 18 (transformer tap changes) for more information. Note: If this light illuminates when the
inverter is in Stop mode, it does not indicate a problem.
High Temp - Indicates that the power transistors inside the inverter are not receiving sufficient
cooling. The inverter will shut down to prevent the unit from overheating. If this light
illuminates, you should call Pillar Service.
Reject Fault Indicates that the reject verification sensor did not sense a bottle moving into the
reject tray. Also illuminates during SETUP when the reject verification sensor is blocked.
Current Trip - Indicates that a short circuit has occurred between the inverter and the coil. The
inverter will shut down to protect the output circuits. If this light illuminates, you should call
Pillar Service.
Under Voltage Trip - Indicates that the supply voltage to the inverter has dropped (as in a
brownout). The inverter will shut down to prevent the inverter from drawing excessive current.
Check the supply voltage.
Over Voltage Trip - Indicates that a voltage surge or other situation has caused an over-voltage
condition within the inverter. The inverter will shut down to protect itself.
Stalled Bottle Fault - When this light is illuminated it is a warning that a Stalled Bottle
condition was detected at the sealing coil. Also lights when rejected bottle button is pressed.
Refer to the Stalled Bottle section in this manual for further information on this system. Note:
Only applies to systems that include this option.
Loose Cap Fault - When this light is illuminated, it indicates that a cap was detected which is
not fully seated on the container or is not threaded evenly causing a fault condition. Also lights
when rejected bottle button is pressed. Refer to the Loose Cap Detector section in this manual
for further information. Note: Only applies to systems that include this option.
Missing Foil Fault - When this light is illuminated, it indicates that a container passed under the
sealing coil that did not have a liner installed, and was not properly sealed. Also lights when
rejected bottle button is pressed. Refer to the Missing Foil Detector section in this manual for
further information. Note: Only applies to systems that include this option.
Zero Speed Fault - When this light is illuminated it is a warning that a Zero Speed Condition
21
OPERATION
was detected at the conveyor. If enabled, the Zero Speed Fault LED will illuminate when there
is a zero speed fault instead of the STALLED BOTTLE FAULT. Note: Only applies to systems
that include this option.
Operator Controls
LED Display - Shows the power level in percent being delivered by the inverter to the sealing
coil.
Power - When pressed the display will read the requested power set point and if the inverter is
running it will return back to actual power when released. Active when green indicator is lit on
button.
Alarm Set - Pressing this button allows the operator to view the Alarm Set Point on the display
and change as required. Active when green indicator is lit on button.
Total Bottle - Indicates the total number of containers that have passed through the sealing coil.
Not available without the optional detection system. Reset by holding the button for 5 seconds.
Rejected Bottle - Indicates the total number of rejects due to a stalled bottle, loose cap, or
missing foil fault. Not available without the optional detection system. Reset by holding button
for 5 seconds.
Total Run Time - Indicates the total number of operating hours on the system. Reset by
holding the button for 5 seconds.
Power Set Point - Digital entry of the percentage of output power. This setting will control the
amount of heating induced in the bottle caps. To change the setting, press the up or down button
next and set for the appropriate level on the display.
Alarm / Time Set Point - Digital entry of the alarm threshold. If the actual power output to the
coil falls below this setting, the alarm circuitry will be activated. This is sometimes called the
loss of seal condition. Note: Set the alarm to "0" if the alarm function in not needed.
Digital entry of the hand held coil on time. The on time (duration) is adjustable anywhere
from 0-10 seconds.
NOTE
Always set the alarm set point below that of the power setting. If the alarm
setting is the same or higher than the power setting, the alarm circuitry will
activate.
Start - Energizes the inverter causing selected power to be delivered to the sealing coil.
22
OPERATION
Stop - De-energizes the inverter to cease delivering power to the sealing coil. This does not shut
off the internal circuitry of the inverter. Also is used as a reset for the under voltage trip, over
voltage trip, and current trip.
Reset - Pressing this button after a stalled bottle, loose cap, or missing foil condition has
occurred will enable the inverter as long as the fault no longer exists. Note: Only applies to
systems that include these options.
The reset button also serves as an alarm silence. If the loss of seal alarm is used, pressing this
button will silence the loss of seal alarm. Note that the alarm can only be silenced if the
capsealer is stopped.
The first push of the reset button will silence the alarm. The second push of the reset button will
clear any fault that is present.
Run/Setup - Pressing this button will toggle between the run and setup mode for the stalled
bottle detector. The setup LED will also light when in the setup mode.
Power Setting
It may be known from previous experience what power setting should be used for a particular cap
and conveyor speed. It is always a good idea to test the setting once a setup has been changed, to
assure that good seals are achieved before running production.
Do not wear jewelry such as watches, rings, or bracelets while working
near the sealing coil. Metal objects can become extremely hot if brought
into close proximity of the sealing coil when power is applied.
Always keep hands clear from under the coil unless you are certain that
the inverter is shut off.
1. Determine the necessary speed of the conveyor. An increase in conveyor speed will reduce the
amount of heat developed in each seal. A proportional increase in inverter output will be
required to maintain seal quality. Once the proper speed has been determined it should remain
constant.
23
OPERATION
2. Insure that the coil is properly mounted and positioned.
3. Set the Alarm setting to "0" or some low setting. Set the power level at some arbitrary value
(such as 50%). Press the start button. Place a bottle onto the conveyor and let it run under the
coil.
4. Retrieve the bottle and allow a few seconds for it to cool. Remove the cap and inspect the seal.
The foil must be completely sealed around the lip of the bottle, without melting into the lip.
Also, the wax must release from the foil.
5. Adjust the power level up or down as needed and test a new bottle. Repeat with a new bottle
each time until a satisfactory seal is obtained.
6. Note the power setting, coil gap, and conveyor speed for future reference.
7. If the alarm will be used set the value to a few percent lower than the power setting. If the alarm
function is not needed, set the control to "0", or at least a value significantly lower than the
power setting.
If it is not possible to get good sealing when the inverter is set at maximum power, either the
output transformer tap needs to be changed or the conveyor speed must be reduced. Refer to
page 18 (transformer tap changes) for more information.
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OPTIONAL EQUIPMENT
Optional Equipment
Stack Light
A three level, high visibility, stacked light assembly mounted to the rear of the inverter to indicate a
Run (green), Stop (red), or Loss of seal (amber) condition. The lights easily mount to the inverter
cabinet and a connector is provided to simplify the installation. This option can also be quickly
added to existing equipment provided that it supports this option. Figure 9 below shows a typical
location for a system with an optional stack light. (Note that this option utilizes the power supply
loss of seal contact and run contact. These contacts will not be available for customer use.)
Figure 9
Optional Stack Light
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OPTIONAL EQUIPMENT
Bottle and Cap Detection System
The Bottle and Cap Detection System utilizes the latest sensor technology to detect one of three
fault conditions, stalled bottle, missing foil, or loose cap. Each one of these faults is discussed in
detail below. Please see the drawing of a typical detection system at the end of this section.
Stalled Bottle Detector
The purpose of the stalled bottle sensor assembly is to detect bottle movement on the conveyor
line and activate an alarm if a bottle becomes stalled under the induction sealing coil. The
stalled bottle option will also shut down the power supply when the fault occurs. If a container
should stall beneath the coil, the foil liner may overheat, resulting in burning of the liner and the
container, resulting in a potential safety hazard. The system senses containers entering the seal
zone and also senses the containers leaving the seal zone. At the same time a third sensor
monitors the conveyor speed and is used to record the proper amount of time for a container to
pass between sensors. Even a slight delay from entrance to exit will cause an alarm to activate.
If it is desirable to disable this option, locate the dip switches on the display circuit board and
turn off switch #1.
The stalled bottle detector requires two sets of photoelectric sensors located at each end of the
sealing coil. Brackets are provided for mounting these sensors to the conveyor system. The
outputs from these sensors are connected to the display circuit board located in the inverter
enclosure. In addition, an optical encoder is also provided, which requires mounting onto the
conveyor shaft at a convenient location. The output of this encoder is also connected to the
display circuit board. Please see the encoder mounting instruction drawing located after this
section.
Specifications
Minimum Conveyor Speed:
7 ft/min (2.13 M/M)
Maximum Conveyor Speed:
250 ft/min (76.2 M/M)
Minimum Cap Diameter:
28 mm
Minimum Distance Between Caps:
1/4 inch (6.4 mm)
Maximum Distance Between Sensors:
48 inches (1219.2 mm)
1
1
TP
PT
Smaller size bottles can be used with this system but the maximum conveyor speed of the system
may change.
TP
PT
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OPTIONAL EQUIPMENT
Note: A minimum opening is required between caps so that the sensors can detect when a bottle
is present and when it isn't. Container shape and neck configurations are also a factor in
achieving reliable operation.
Features
Indicator Lamp - Light located on display panel lights when a stalled bottle fault occurs.
Reset Button - Allows the operator to silence the alarm during a stalled bottle fault.
Fail Safe Operation The system will also monitor the conveyor speed, and will give a
stalled bottle fault if the conveyor speed drops below 7 ft/min (2.13 M/M).
Reject Counter - A display that shows the number of rejects caused by stalled bottle faults.
Function
During normal operation, the stalled bottle system will monitor bottles passing under the sealing coil
and indicate a fault condition should a container stall or jam. When a stalled bottle fault occurs, the
system will stop the inverter output to the sealing coil and open an external contact at terminals
[111] and [112] which is provided for customer use. (Note: this contact is closed during a normal
run condition.) The interlock contact will turn off the power supply preventing damage to the
product and the sealing coil.
Once a stalled bottle fault occurs, the operator must remove all containers between the sensors
before trying to reset the fault. If the operator does not clear all containers between the sensors, a
false indicating fault will occur.
This stalled bottle system will also monitor the entrance sensor. Should the entrance sensor not
sense a passing bottle and the exit sensor does, a fault condition will occur. This allows for fail safe
operation and eliminates the possibility of a stall condition not being detected. If any of the sensors
are miss-aligned or damaged in any way, the system will detect a problem and a fault condition will
occur preventing the system from operating.
The stalled bottle faults are stored in memory and the total number of faults that occurred can be
seen by pressing the rejected bottle count button. Each time the rejected bottle count button is
pressed it will sequence through all the available options, like stalled bottle, missing foil, loose cap,
etc. You can determine which faults have occurred by the LED indicators. Holding the rejected
bottle count button in for a period greater than 5 seconds will reset all the fault counters.
Missing Foil Detector
The purpose of the missing foil detection system is to provide a warning to the operator in the
event that a container passes under the sealing coil that did not have a liner installed. If a
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OPTIONAL EQUIPMENT
container passes under the inductive sensor that does not have a foil present, the inductive sensor
will send a signal to the microprocessor, the processor will then provide a signal to alert the
operator. This option does not shut down the inverter, but can be used with a reject mechanism
to remove defective containers from the conveyor line. If it is desirable to disable this option,
locate the dip switches on the display circuit board and turn off switch #2.
The missing foil system consists of a photoelectric sensor that detects the presence of a container
at the same time that the inductive sensor is looking for a foil under it. (The photoelectric sensor
is the same one used for the stalled bottle function.) The outputs from both of these sensors are
connected to the display circuit board the inverter enclosure. In addition, the optical encoder
mentioned in the stalled bottle section is also required.
Features
Indicator Light - Light that is located on the display panel, which indicates when a missing foil
fault has occurred.
Adjustable Fault Contact A timed contact used to activate a bottle reject.
Dependable Operation - The sensing of the container and the foil at the same time allow for failsafe operation and dependable detection of foils.
Reject Counter - A display that shows the number of rejects caused by missing foil faults.
Function
During normal operation, the bottles pass under the foil sensor and past the bottle sensor at the same
time. As long as the foil sensor detects a foil while the bottle sensor is activated the system will
continue to operate normally. If a cap without a foil should pass under the foil sensor, a signal will
not be received by the microprocessor and this will cause a foil detection fault to occur. When this
happens, the fault light on the display panel will light and the reject contact on terminals [83] and
[84] will close, indicating a missing foil was detected. This contact can be used to activate an alarm
or to activate a reject mechanism to remove the container from the conveyor. Please see the Setup
and Operation section below for reject setup.
The missing foil faults are stored in memory and the total number of faults that occurred can be seen
by pressing the rejected bottle count button. Each time the rejected bottle count button is pressed it
will sequence through all the available options, like stalled bottle, missing foil, loose cap, etc. You
can determine which faults have occurred by the LED indicators. Holding the rejected bottle count
button in for a period greater than 5 seconds will reset the all the fault counters.
Loose Cap Detector
The loose cap detection system is used to detect the presence of a cap that is not fully seated, or a
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OPTIONAL EQUIPMENT
crooked cap, or even a container which is not setting flat on the conveyor. The result of any of
these conditions will cause an output signal to an external relay which can be used to activate an
alarm device, or provide the signal to a reject mechanism on the conveyor. If it is desirable to
disable this option, locate the dip switches on the display circuit board and turn off switch #3.
The loose cap system consists of a photoelectric sensor and a retro-reflective laser sensor that are
mounted at the exit of the sealing coil. The photoelectric sensor senses the presence of a container
exiting the sealing coil area. (The photoelectric sensor is the same one used for the stalled bottle
function.) The retro-reflective laser sensor is looking for a cap that is not at the correct height on the
conveyor. The outputs from both of these sensors are connected to the display circuit board the
inverter enclosure. In addition, the optical encoder mentioned in the stalled bottle section is also
required.
Features
Indicator Light - Light that is located on the display panel indicates when a loose cap fault has
occurred.
Adjustable Fault Contact A timed contact used to activate a bottle reject.
Dependable Operation - The sensing of the container and the cap at the same time allow for failsafe operation and dependable detection of loose or crooked caps.
Reject Counter - A display that shows the number of rejects caused by loose cap faults.
Function
During normal operation the loose cap sensors will detect a container passing through the sealing
coil with the bottom sensor and also look for no obstruction of the beam with the upper sensor at the
same time. If the upper sensor beam is broken while the lower sensor detects a container, a fault will
occur and a signal is fed back to the microprocessor. The microprocessor will activate the reject
contact on terminals [83] and [84] indicating a loose cap was detected. This contact can be used to
activate an external alarm or to activate a reject mechanism on the conveyor.
When a cone or dispenser style cap is being used, dip switch #6 needs to be in the on position. Dip
switch #6 is located on the display circuit board. During normal operation, the upper sensor will
detect the raised portion of the cap while the bottom sensor detects the base of the cap. When the
upper sensor beam is broken for a period greater than the width of the raised portion recorded during
setup, the reject contact will be activated.
The loose cap faults are stored in memory and the total number of faults that occurred can be seen by
pressing the rejected bottle count button. Each time the rejected bottle count button is pressed it will
sequence through all the available options, like stalled bottle, missing foil, loose cap, etc. You can
determine which faults have occurred by the LED indicators. Holding the rejected bottle count
button in for a period greater than 5 seconds will reset all the counters.
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OPTIONAL EQUIPMENT
Setup and Operation
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
30
Attach the encoder to the conveyor per drawing AI529-39 (Figure 10). Use the supplied
shoulder bolt to attach the encoder to a conveyor shaft. The conveyor shaft will need to
be tapped for a 5/16 18 thread.
Route the encoder cable from the sealer power supply to the encoder. Ensure that the
cable will not get entangled in the conveyor or any other moving part.
Turn on the power to the sealer power supply.
Adjust the coil height to container being sealed. See instructions on adjusting the coil
elsewhere in this manual.
At the entrance to the sealing area there are two photoelectric sensors. These are
designated as sensor #1. One sensor emits a red beam of light, where as the other
receives the beam of light. On the receiver there is a green light (power on) and a yellow
light (light beam received).
Place a container with a cap at the entrance sensor pair.
Loosen the four bolts on the sensor bracket and gently lower the entrance sensors until
the yellow light (light beam received) on the receiver goes out. Preferably adjust the
sensors to just below the bottom of the cap.
Tighten the four bolts on the sensor bracket.
At the exit to the sealing area there are two photoelectric sensors. These are designated
as sensor #2. One sensor emits a red beam of light, where as the other receives the beam
of light. On the receiver there is a green light (power on) and a yellow light (light beam
received).
Place a container with a cap at the exit sensor pair.
Loosen the four bolts on the sensor bracket and gently lower the exit sensors until the
yellow light (light beam received) on the receiver goes out. Preferably adjust the sensors
to just below the bottom of the cap.
Tighten the four bolts on the sensor bracket.
Place a container with cap and foil under the inductive foil sensor (designated as sensor
#4).
Lower the inductive foil sensor by loosening the lock nuts on the sensor barrel. Lower
until the indicator light on the foil sensor is illuminated. Make sure that the foil sensor
will not obstruct the light beam of the loose cap sensor.
The loose cap sensor is a retro-reflective laser sensor. This sensor is designated as sensor
#3. The loose cap sensor is located on the same bracket as the foil sensor. This laser
sensor utilizes a reflector mounted on a bracket across the conveyor from the laser. If the
beam is broken, a loose cap fault has occurred.
Adjust the sensitivity of the loose cap sensor by turning the potentiometer on the back of
the sensor until the yellow LED goes out. Turn the potentiometer back until the yellow
LED just comes on. The yellow LED must be on solid (not flashing) with out a container
present.
Place a container between the loose cap sensor (sensor #3) and the reflector.
Lower the loose cap sensor with the thumbscrew (turning counter-clockwise) until you
see the laser beam on the top of the cap.
Raise the loose cap sensor with the thumbscrew (turning clockwise) to the desired height
required for a loose cap fault.
OPTIONAL EQUIPMENT
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
Turn the conveyor on.
Push RUN/SETUP on the sealer power supply.
There should be an encoder reference number on the 3-digit display and the green setup
light is on.
Place a good container with a cap and foil on the conveyor and let it pass through all of
the sensors.
As the container passes by the entrance sensor (sensor #1) the yellow stalled bottle fault
light on the sealer display panel will flash. As the container passes by the exit sensor
(sensor #2) the yellow stalled bottle fault light on the sealer display panel will flash. As
the container passes by the foil sensor (sensor #4) the yellow missing foil fault light on
the sealer display panel will flash. The yellow loose cap fault light will not illuminate
during setup.
If any of these lights did not flash, there is a problem with the sensors (alignment, power,
etc).
Push RUN/SETUP on the sealer power supply.
The green setup light will go out.
If the stalled bottle fault, loose cap fault, or missing foil fault lights are on at this time,
then the setup is invalid. Readjust the sensors and re-run the setup procedure.
Start the sealer power supply.
Run a good container through the sensors to verify the operation. No faults should occur.
Run a container through the sensors with out a foil to verify a foil fault condition. The
missing foil fault light should come on.
Run a container through the sensors with a loose cap to verify a loose cap condition. The
loose cap fault light should come on.
Run a container through the entrance sensor only. Remove the container before it gets to
the exit sensor. The stalled bottle fault light should come on and the sealer will shut off.
Clear all of the bottles from the sensor area.
Push RESET on the sealer power supply.
Start the sealer power supply.
The zero speed fault light will illuminate when the encoder reference number is below
40.
The setup of the detection system is complete.
If at anytime the container size changes or the sensor are adjusted a setup must be
performed.
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OPTIONAL EQUIPMENT
Figure 10
32
Encoder Mounting
Figure 11
POWER S UPPLY S TAND
MUS T BE LOWERED BEFORE
MOVING MACHINE
CAUTION
4 75 IN D U S TR IALD R IVE
H AR T LA N D , W I53029
( 262) 912- 7200
OPTIONAL EQUIPMENT
Typical Bottle and Cap Detection System with Reject & In-feed Bottle Stop
33
OPTIONAL EQUIPMENT
Pneumatic Reject
A pneumatic reject is available to work in conjunction with the missing foil and/or loose cap
detection system. The reject is activated whenever these faults occur. The reject cylinder
bracket is simply mounted to the portable stand. The reject signal is determined by the sensor
system described above. A source of clean, dry compressed air of at least 80 psi is required to
operate the cylinder. Please see the reject setup instructions below to adjust the operation of the
pneumatic reject.
Setup and Operation
1.
2.
3.
4.
Mount the reject tray to the conveyor.
Attach the airline to the pneumatic solenoid that is located under the sealer power supply.
A ¼ airline fitting is supplied. A source of clean, dry compressed air of at least 80 psi
is required to operate the pneumatic cylinder.
Route the cables from the sealer power supply to the two photoelectric sensors (reject
verification sensors #6) on the reject tray. It does not matter which cable connects to
which sensor. Ensure that the cables will not get entangled in the conveyor or any other
moving part.
Adjust the timed contacts. See the reject setup instructions below to adjust the operation
of the pneumatic reject.
Reject Control Setup
To setup the timed contact closure for an external reject mechanism, press the Run/Setup button on
the operator panel. The Setup LED on the operator panel will illuminate. Press the Power button.
This readout represents the number of encoder pulses that the relay contact at terminals [83] and [84]
will remain closed for or Duration. To adjust this value (1-999), use the Duration up/down buttons.
The Duration value is measured in encoder pulses and must be determined by the formula shown
below. It should be set equal to but not greater than the equivalent encoder pulses of one container
plus the minimum container spacing as shown in figure 13 on page 36.
Duration Value = PPR / ( 3.1416*( OD + .5 ) ) * ( Container Width + Spacing )
OD (inches) - Outside Diameter of the conveyor sprocket driving the encoder. See Figure 12.
PPR - Encoder pulses per revolution.
Container Width plus Spacing between containers in inches. See Figure 13.
EXAMPLE:
Lets assume that you have a Sprocket Outside Diameter of 5 inches, a 360 ppr encoder, a
container width of 2 inches, and a space between containers of 1 inch.
34
OPTIONAL EQUIPMENT
Since
OD + .5 = 5.5 inches
Container Width + Spacing = 3 inches
PPR = 360
Then
5.5 X 3.1416 = 17.28
And
360 / 17.28 = 20.83
And
20.83 X 3 =
or Encoder pulses per linear inch of conveyor travel.
Duration Value = 62.5 Adjust the Duration value to 62 or less.
With the Setup LED illuminated, press the Alarm button to view the reject delay. This number
represents the number of encoder pulses that the relay contact will be delayed in closing. The delay
is from the point of sensing to the reject mechanism. To adjust this value (1-999), use the Delay
up/down buttons. Use the encoder pulses per inch calculated above to set the delay value.
To test the reject parameters, remove the cap from a container and place the container on the
conveyor ahead of the sealing coil and sensors. Adjust the reject parameters and repeat until the
reject mechanism expels the container as desired. Replace the cap on the container and run the
container through the sensor system again.
Press the Run/Setup button to return to the run mode. The Setup LED should now extinguish. If
neither of the reject parameters were altered, the Missing Foil Fault indicator will illuminate.
Press the reset button to turn off the fault light and the system is ready to operate.
Figure 12 Conveyor Sprocket Diameter
35
OPTIONAL EQUIPMENT
Figure 13 - Setting Container Spacing
The reject verification detection system is used to verify that a container has been removed from
the conveyor once the system has decided to reject it. This system consists of a sensor placed at
the entrance of the reject tray. If a reject verification has not been detected after a reject, the
power supply will turn off, the Reject Fault LED on the front panel will illuminate and the reject
fault relay will be energized. To reset this fault and restart the power supply, the RESET or
STOP button must be pressed. The system will wait approximately 600ms after the reject relay
is de-energized or until the next reject (whichever is shorter) to detect the container exiting the
conveyor before issuing a fault. A Reject Fault may also occur if the reject verify sensor is
blocked.
In Setup mode, the Reject Fault LED on the front panel will illuminate when the reject
verification sensor is blocked.
In-feed Bottle Stop
The in-feed bottle stop is an air-actuated gate that stops bottles from entering an inactive sealing
area when the machine is in STOP mode or the power is turned off. This eliminates the risk of
36
OPTIONAL EQUIPMENT
unsealed product getting through production lines. It works directly with the LOS (loss of seal
indicator) built-in to the induction sealer's power supply.
The pneumatic mechanism actuates a 5" stroke cylinder that blocks passage of bottles under the
sealing head. The In-feed bottle stop gates incoming bottles when there is an alarm condition or
there is no energy to the sealing coil (head). If the sealing energy drops below the operator s
output set point, causing an inactive sealing area, the gate closes. When the energy returns and is
once again above the operator s set point, the gate opens and bottles are free to move into the
active sealing area.
Tap Selector Switch
An output transformer load compensating selector switch is available to change the output taps
on the inverter. The switch is located on the back of the inverter enclosure. See Figure 14. The
switch is interlocked to the control circuits so the power supply will turn off prior to a tap
change. The use of this switch eliminates the need to remove the inverter enclosure cover in
order to change taps.
37
OPTIONAL EQUIPMENT
Figure 14
Tap Selector Switch
IQ/OQ Documentation
Installation qualification protocol and operation qualification protocol documents are available for
the specific system ordered. These documents are tailored specifically for the customer and
equipment purchased.
38
OPTIONAL EQUIPMENT
Conveyor System
A conveyor is available to attach to the portable coil support. The conveyor is five feet long
with a 4.5-inch wide belt and is constructed of stainless steel. A DC motor controller is available
in either 120 VAC or 240 VAC input voltage. The controller allows speed control from 0-60
FPM. The conveyor includes single high guide rails. Please see Figure 15.
39
475 IN D U S TR IALD RIVE
H A R T LAN D , W I53029
( 262) 912-7200
OPTIONAL EQUIPMENT
Figure 15
40
Conveyor System
SERVICE
Service
Inverter
Inspection
Maintenance is limited to keeping the front panel and fan filters clean. Use a soft cloth and
window cleaner or mild detergent to clean the front panel. Do not use solvent. Solvent will
damage the plastic panel overlay. The fan filter located on the supply's right hand side should be
cleaned with plant air or vacuumed occasionally. Disconnect incoming power before cleaning.
Check the fan for accumulation of dust. Remove any dust carefully with dry compressed air.
Troubleshooting
Inverter won't start.
- If the alarm circuit is being used to interlock the inverter, check the Alarm Fault indicator.
The alarm setting must be lower than the power setting.
- An external customer interlock may be active.
- Check FAULT lights on the inverter. Refer to page 20 to interpret the lights.
- Check the control transformer fuse located on the transformer board in the inverter
enclosure.
- If the inverter shut down due to high temperature, the inverter is not receiving sufficient
cooling. The ambient temperature may be too high.
Over Volt fault.
- Indicates that a voltage surge or other situation has caused an over-voltage condition within
the inverter. The inverter will shut down to protect itself.
- Loose or open connection between the inverter and the coil.
- Output transformer tap is set too high for the coil being used.
Under Volt fault.
- Check for a short circuit in the cable running to the coil.
- Excessive coil loading. Too many bottles under the coil at once.
- Indicates that the supply voltage to the inverter has dropped (as in a brownout). The inverter
will shut down to prevent the inverter from drawing excessive current. Check the supply
voltage.
Current fault.
41
SERVICE
- Loose connections between the output transformer and the coil.
- Excessive coil loading. Too many bottles under the coil at once.
Impedance Low indication or insufficient sealing.
- Indicates that an impedance mismatch has occurred. This condition occurs when the load on
the inverter is higher than it can deliver. Change output transformer tap.
(Note: It is normal for the Low Impedance lamp to be lit when the inverter is in Stop mode.
It should go out when the Start button is pressed.)
Impedance High indication.
-
If this light should illuminate when the inverter is in Stop mode, it does not indicate a
problem. If it illuminates while the inverter is running, there may be a problem inside the
inverter or coil. Typically this indicates that a capacitor within the coil assembly has opened
up. In this event, please contact Pillar Service.
An optical sensor does not function properly.
-
Switch to Setup mode and check sensor operation.
See that the connector is plugged into the correct receptacle.
If the sensor is working electrically
Move the support bracket to align sensors.
Try sensing the bottle instead of the cap.
To disable options
- To disable the stalled bottle option, change dip switch #1 to the off position. (Dipswitch #1
is located on the display circuit board.)
- To disable the foil detector option, change dip switch #2 to the off position. (Dipswitch #2 is
located on the display circuit board.)
- To disable the loose cap detector option, change dip switch #3 to the off position.
(Dipswitch #3 is located on the display circuit board.)
- To change the reject position from exit to entrance, change dip switch #4 to the on position.
(Dipswitch #4 is located on the display circuit board.)
Coil Support
Clean the lead screw if it has accumulates dirt. A light application of silicone oil on the screw thread
will keep the crank turning smoothly. Do not use cleaners or lubricants that are not compatible with
the Delrin slide blocks.
Sealing Coil
If the coil is routinely mounted and dismounted, check the condition of the locking handle to ensure
proper operation, apply light grease when required.
42
SERVICE
Check the fan for accumulation of dust. Remove any dust carefully with dry compressed air.
Specifications
Input:
Voltage
208/240 VAC +/- 10% (240 VAC only for CE version)
50/60 Hz
1 phase
Current
13A /11.3 A
Power
2.7 kVA
Output:
Power
Voltage
2 kW
low tap (H2), 268 V rms
B
B
middle tap (H3), 350 V rms
B
B
high tap (H4), 440 V rms
B
Current
B
11 A
Frequency
45 to 60 kHz
Environmental Conditions:
Recommended for Indoor Use Only
Maximum Ambient Temperature:104 o F (40 o C)
P
Humidity -
P
P
P
-20% to 90% non-condensing
43
SERVICE
Spare Parts
Following are lists of recommended spare parts. Two levels of parts kits are available, standard and
a calibrated circuit board set. Some of the parts are identified in Figures 19 and 20 on pages 48 and
49.
Standard spare parts for the 2 kW Unifoiler
Description
Designator
Incoming line fuses 20A
Control transformer fuse
Snubber board fuses
Inverter IGBT, 600V, 150A
Diode Module
Cooling fan
Temperature switch
FU3, FU4
FU1
DSB
1Q
RECT. 1
FAN1
TS1
Calibrated circuit board set contains all of the printed circuit boards for the 2 kW Unifoiler.
Spare Parts for Stalled Bottle Sensor
Fiber Optic sensor amplifier
Optical sensor
Encoder
Spare Parts for Missing Foil Sensor
Fiber Optic sensor amplifier
Optical sensor
Inductive foil sensor
Encoder
Spare Parts for Loose Cap Sensor
Fiber Optic sensor amplifier
Optical sensor
Encoder
44
475 I NDUSTRIAL DRIVE
HARTL AND, WI 53029
(26 2) 912 -7200
SERVICE
Dimensions
Figure 16
Outline Drawing 2kW C
45
46
Figure 17
POWER S UPPLY STAND
MUS T BE LOWERED BEFORE
MOVING MACHINE
CAUTION
4 75 I NDUSTRIA L D RIVE
H ARTL AND, WI 5 30 2 9
(2 62 ) 9 12 -7 20 0
HARTL AN D, WI 53 02 9
(2 62 ) 91 2 -72 00
4 7 5 INDUS TRIAL DRIVE
SERVICE
Outline Drawing 2kW U
475 IN D U S TR IALD RIVE
H A R T LAN D , W I53029
( 262) 912-7200
SERVICE
Figure 18
Outline Drawing 2kW - UC
47
SERVICE
Figure 19
48
External Components
SERVICE
Figure 20 - Internal Components
49
SERVICE
50
SERVICE
51
SERVICE
52
NOTE:
BOTH EMITTER AND RECIEVER
ARE WIRED IN PARALLEL.
SERVICE
53
SERVICE
54
SERVICE
55
SERVICE
56
NOTE:
BOTH EMITTER AND RECIEVER
ARE WIRED IN PARALLEL.
SERVICE
57