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INDUCTION CAPSEALING SYSTEMS
Air Cooled Conveyor and Hand Held System
Model #
Serial #
Manual
PP1239-20
OPERATOR'S MANUAL
UniFoiler 3000
CE, ETL Approved
Pillar Technologies
475 Industrial Drive
Hartland, WI 53029
(262) 367-3060
Comment: PP1239-20- Capsealing
Systems, UniFoiler 3000, air cooled.
Independent Stalled Bottle/Foil Detector,
CE & ETL Approved.
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Summary of Contents for Pillar UniFoiler 3000
- Page 1 Comment: PP1239-20- Capsealing Systems, UniFoiler 3000, air cooled. Independent Stalled Bottle/Foil Detector, CE & ETL Approved. OPERATOR'S MANUAL INDUCTION CAPSEALING SYSTEMS UniFoiler 3000 Air Cooled Conveyor and Hand Held System CE, ETL Approved Model # Serial # Manual Pillar Technologies...
- Page 2 November 30, 2001 Convert to MS Word. ©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.
- Page 3 Declaration of Conformity The Pillar Induction Capsealing System, consisting of Power Supply Unifoiler 3000 Models DB6559-6, DB6559-8, AB6559-9, AB6559-10, AB6559-11, AB6559-12 or AB6559-13, and either Universal Coil, Model CB6665-2 or Hand Held Coil Model BB665-3, is in conformity with the EMC Directive 89/336/EEC in accordance with the following Standards:...
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Page 4: Table Of Contents
CONTENTS CAUTIONARY STATEMENT ..................vi Introduction..........................1 About This Manual ....................1 Product Description ....................1 Some Terms ......................2 Installation..........................5 Conveyor Coil Support ....................5 Hand Held Coil Support...................6 Power Supply ......................7 Conveyor Sealing Coil.....................9 Hand Held Sealing Coil ..................10 Wiring ........................11 Setup ..........................14 Hand Held Coil ......................14 Channel Coil ......................15 Universal Coil ......................15... - Page 5 FIGURES Figure 1 - Conveyor Coil support and components ……………………………………. Figure 2 - Checking that the coil is level ………………………………………………… Figure 3 - Hand Held Coil Sealing Area ………………………………………………… Figure 4 - The System Components ……………………………………………………. Figure 5 - Adjusting the height of the channel coil …………………………………….. Figure 6 - Adjusting the universal coil ……………………………………………………...
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Page 6: Cautionary Statement
CAUTIONARY STATEMENT 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. -
Page 7: Introduction
This manual contains information for installation, operation, maintenance and repair. It should be read by installers, operators and maintenance personnel. This manual covers the UniFoiler 3000 air-cooled series of capsealing systems. Other systems consist of individual components. Therefore, some references in the manual may not reflect your particular equipment configuration. -
Page 8: Some Terms
• Operator panel is mounted directly to the front of the power supply, and compact size allows for easy mounting on your conveyor line. • A standardized coil mounting system accepts any Pillar UniFoiler 3000 sealing coil. • Several styles of sealing coils are available to adapt to a variety of sealing needs. The coils are easily located, adjusted, and connected electrically. - Page 9 Introduction 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 electro–magnetic field.
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Page 11: Installation
Installation Installation Conveyor Coil Support The coil support is supplied with conveyor mounted coils, and 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. -
Page 12: Hand Held Coil Support
Installation The support must be mounted 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 2. -
Page 13: Power Supply
Installation Figure 3 – Hand Held Coil Sealing Range Inverter The power supply is supplied in a 10.62" x 16.63" x 15.29" stainless steel enclosure. The operator panel is located on the front of power supply as shown below in Figure 4. The input and output connections to the power supply are located on the rear heatsink assembly. -
Page 14: Figure 4 - The System Components
Installation Figure 4 – The UniFoiler System Components The standard power cable lengths from the inverter to the sealing coil are ten feet on the hand held coil system. The conveyor style system is supplied with standard ten-foot cables, which can be removed from both the power supply and the coil. -
Page 15: Conveyor Sealing Coil
Installation Customer alarm or interlock circuitry is also provided and wired to the 10 pin connector (RECP. 2) on the back of the heatsink. A plug is provided for ease of connection should any of these options be used. A jumper is normally provided between pins 3 and 4, and must be removed if the interlock circuit is connected. -
Page 16: Hand Held Sealing Coil
Installation Connect the power cable to the coil. It is very important that the connector is securely fastened and properly positioned. Hand Held Sealing Coil The hand held coil in intended for low volume production runs and for special packaging needs which prohibit the use of a conveyor system. -
Page 17: Wiring
Installation Wiring Besides power input and interlocking, there are several connector terminals available that can be used to incorporate the capsealing system into other control wiring. The interconnection wiring diagram appears on page 32. At the end of the manual there is a complete system schematic diagram. - Page 18 Installation If this feature is not used, a jumper should be installed across these terminals. Low output alarm - This alarm activates the user alarm indicator and alarm relay, which changes state, to signal a loss of seal condition. A normally open contact is available. Use these terminals to trigger an alarm or light when the capsealing system is not delivering the correct output.
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Page 20: Setup
Installation Setup There are different procedures for setting up coils, depending on the style. Some coils will require proper adjustment of conveyor guides, others will require a pivot adjust depending on cap size, and the hand held coils require no adjustment. Hand Held Coil The hand held coil is normally used for low volume applications, or on applications which prohibit the use of a conveyor style system. -
Page 21: Channel Coil
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. 1. -
Page 22: Figure 6 - Adjusting The Universal Coil
Setup 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 outside of one edge of the bottle cap. The mark on the exit end of the coil is to be positioned outside of the opposite edge of the bottle cap. -
Page 23: Before Starting
Setup Before starting 1. Check that the coil has been mounted and aligned as described above. 2. Check that the power cable is connected and is properly seated and secure. - Page 24 Setup This page left blank...
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Page 25: Operation
Operation Operation Inverter The power supply delivers a controlled level of high frequency power to the sealing coil. The operator panel allows the user to control the level of power. On hand held systems, the sealing time during which power is supplied to the coil is also adjustable. The power supply includes a rectifier section, an inverter and a series inductor for delivering a high frequency, sinusoidal output to the sealing coil. - Page 26 The power supply will shut down to prevent the unit from overheating. If this light illuminates, you should call Pillar Service. The temperature switch has an automatic reset, so once the unit has cooled down you can press the stop switch and restart the unit.
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Page 27: Operator Controls
Operation Operator Controls LED Display - Shows the power level in percent being delivered by the power supply to the sealing coil. Power - Normal default mode for the LED display when using a conveyor coil. When pressed the display will read the actual power level of the power supply. Active when green indicator is lit on button. -
Page 28: Power Setting
Operation Reset - Pressing this button will reset a stalled bottle or missing foil fault condition as long as the fault no longer exists. Run/Setup -Pressing this button will toggle between the run and setup mode for the stalled bottle detector. The setup LED will light when in the setup mode. Power Setting It may be known from previous experience what power setting should be used to seal a particular cap at a known time or conveyor speed. - Page 29 Operation 6. Note the power setting for future reference. 7. Optionally, set the alarm value to a few percent lower than the power setting. If the alarm function is not needed, set the control to "00", or at least a value significantly lower than the power setting.
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Page 31: Service
Service Service Maintenance Power Supply: Check the heatsink for accumulation of dust. Remove any dust carefully with dry compressed air. Coil Support: Clean the lead screw if it accumulates dirt. A little silicone spray 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. - Page 32 Stop mode. It should go out when the Start button is pressed.) .. Impedance High indication. - There is a problem in the power supply. Contact Pillar Service. .. High Temp. - Check to see if ambient temperature around cabinet is 40 C (105 ) or less.
- Page 33 Service .. Missing Foil Fault. - Used with optional stalled bottle / missing foil detector circuit. Indicates a cap without a liner passed under the sealing coil. - Remove fault. Restart system.
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Page 34: Spare Parts
Service Spare Parts Kits AN818-8 Standard Parts Kit (120 VAC, ETL Version) Description Qty. Designator Temperature Switch Rectifier RECT100 Transistor (MosFet) Q1-Q4 Capacitor C100, C101 Fuse 1A, 250 Volt FU1, FU2 Fuse 15A, 250 Volt F1, F2 AN818-9 Deluxe Parts Kit (120 VAC, ETL Version) Includes all AN818-8 plus: Description Qty. -
Page 35: Specifications
Service Specifications Input - Voltage 108 to 132 VAC 216 to 264 VAC 50/60 Hz 50/60 Hz 1 phase 1 phase Current 15.0 A @ 120V 8.0 A @ 240V 1.6 KVA 1.6 KVA Output - Power 1 KVA 1 KVA Voltage 175 V 175 V... -
Page 36: Dimensions
Service Dimensions Figure 8 – Coil Support Dimensions... -
Page 37: Internal Components
Service Figure 9 - Enclosure Dimensions Figure 10 - Internal Components... -
Page 38: Figure 11 - Interconnect
Service Figure 11 – Connection Diagram... -
Page 39: Figure 12 - Schematic
Service Figure 12 – Electrical Schematic...
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