Pillar UniFoiler 3000 User manual

OPERATOR'S MANUAL
INDUCTION CAPSEALING SYSTEMS
UniFoiler 3000
Air Cooled Conveyor and Hand Held System
CE, ETL Approved
Model #
Serial #
Manual Pillar Technologies
PP 239-20 475 Industrial Drive
Hartland, WI 53029
[phone]
Comment:
PP12 9-20- Capsealing
Systems, UniFoiler 3000, air cooled.
Independent Stalled Bottle/Foil Detector,
CE & ETL Approved.

ii
Printed on 8 May 07
Edit History:
May 28, 999 First publication.
November 30, 200 Convert to MS Word.
© 999, 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.

iii
Declaration of Conformity
The Pillar Induction Capsealing System, consisting of Power Supply Unifoiler 3000 Models
DB6559-6, DB6559-8, AB6559-9, AB6559- 0, AB6559- , AB6559- 2 or AB6559- 3, 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:
Emissions: EN 550 : 99 Class A, Group 2
Immunity: EN 50082-2: 995
______________________________________
Richard J. Washebeck, Director of Engineering
Safety Standards (pending)
This equipment is certified by Intertek Testing Services, 7435 4
th
Street North, Oakdale, MN
55042 to be compliant with the following Safety Standards, and bears the ETL Mark to certify as
such:
UL 0 2, Standard for Power Units Other Than Class 2,
CAN/CSA C22.2 No. 07- , Commercial and Industrial Power Supplies:
Models: AB6559-9, AB6559- 0, AB6559- , AB6559- 2
European Low Voltage Directive:
EN 605 9- , Safety in Electroheat Installations - Part : General Requirements
EN 605 9-3, Safety in Electroheat Installations - Part 3: Particular Requirements for Induction
and Conduction Heating and Induction Melting Installations.
Models: AB6559- 3

iv
CONTENTS
CAUTIONARY STATEMENT ....................................................................................... vi
Introduction..........................................................................................................................
About This Manual ..................................................................................................
Product Description .................................................................................................
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 ......................................................................................... 0
Wiring ....................................................................................................................
Setup ................................................................................................................................ 4
Hand Held Coil ...................................................................................................... 4
Channel Coil .......................................................................................................... 5
Universal Coil ........................................................................................................ 5
Before starting........................................................................................................ 7
Operation............................................................................................................................ 9
Inverter................................................................................................................... 9
Diagnostic Lights................................................................................................... 9
Operator Controls...................................................................................................2
Power Setting.........................................................................................................22
Service................................................................................................................................25
Maintenance...........................................................................................................25
Troubleshooting .....................................................................................................25
Spare Parts .............................................................................................................28
Specifications.........................................................................................................29
Dimensions ............................................................................................................30
Internal Components..............................................................................................3

v
FIGURES
Figure - Conveyor Coil support and components ……………………………………. 5
Figure 2 - Checking that the coil is level ………………………………………………… 6
Figure 3 - Hand Held Coil Sealing Area ………………………………………………… 7
Figure 4 - The System Components ……………………………………………………. 8
Figure 5 - Adjusting the height of the channel coil …………………………………….. 5
Figure 6 - Adjusting the universal coil …………………………………………………… 6
Figure 7 - Operator panel ………………………………………………………………… 9
Figure 8 - Coil support dimensions …………………………………………………….. 30
Figure 9 - Enclosure dimensions ………………………………………………………. 3
Figure 0 - Internal components ……………………………………………………….. 3
Figure - Interconnect …………………………………………………………………. 32
Figure 2 - Schematic …………………………………………………………………… 33

vi
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. Areas in this manual concerning safe operation are identified with the
following “Safety” legend:
Some precautionary measures are listed here:
The capsealing system creates an electro–magnetic field that will cause heating in metal objects
brought into proximity of the sealing coil. Rings, watches, bracelets, or other jewelry should
not be worn when working near the coil. Serious burns could result if these items are worn
and brought near the coil.
Input power must always be disconnected at the source before service or setup of the equipment.
All guards must be in place before starting the equipment.
Proper maintenance of the equipment, including periodic inspection, is necessary to maintain the
highest degree of safety.
Any moving parts can cause injury.
Persons who have comments or questions regarding the safe operation and service of their
equipment are encouraged to contact the Service Department of Pillar Technologies.

Introduction
Induction Capsealing System
UniFoiler 3000
Introduction
About This Manual
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. 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 by telephone at [phone], extension 240.
Product Description
An induction capsealing system is used to apply a hermetic seal over the mouth of a jar or bottle.
The purpose of the seal is to provide evidence of tampering, preserve freshness of the contents or
prevent the contents from leaking from the bottle.
A special plastic cap containing an aluminum foil disk is used. After the cap is screwed onto the
bottle, it is passed underneath a sealing coil. This coil radiates a high-frequency electro–
magnetic field that causes the aluminum disk to heat up. Plastic laminated to this disk softens
and fuses to the mouth of the bottle.
Features:
• The power supply employs MOSFET technology. The MOSFET is a rugged, state-of
-the-art transistor device now being used in critical, high power circuitry for military and
commercial aircraft.
• The power supply enclosure is forced-air cooled and does not require plumbing to a water
cooler system.

2 Introduction
• The power supply is designed for local connection to the sealing coil. The system is made of
watertight electrical components designed for wash-down applications. The power leads
from the inverter to the coil can be of any practical length since they are not water-cooled.
On the hand held system, the leads are provided as part of the coil, and are 0 feet (3 meters)
in length.
• 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. All the coils are air-cooled and
require no water cooling for operation.
Some Terms
Some terms used throughout this manual:
Tank Capacitor - Located inside the enclosure that covers the top of the sealing coil is a
capacitor. It works together with the sealing coil to generate the high-energy electro–magnetic
field. Locating the capacitor at the coil eliminates the need for heavy, water- cooled leads to the
coil.
MOSFET - Metal-Oxide-Field-Effect-Transistor - A type of transistor that can accommodate
high frequency switching for inverters.
Impedance - Relationship between voltage and current. 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 metal passing through the sealing
coil's electro–magnetic field.
Induction Heating - The phenomenon causing electrical current to flow in a charge of material
to be heated.
Inverter - This is the device that changes direct-current power to alternating current, high
frequency power and sends to the sealing coil.
Transformer - The inverter contains a transformer that couples its output to the sealing coil.
Different size bottle caps will load the sealing coil differently. The inverter automatically adjusts
to allow maximum power transfer into the cap.

Introduction 3
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.
Hand-held Coil - A special sealing coil intended for low volume production requirements.
Designed for specific packaging needs which prohibit the use of conveyor style systems. This
coil is held in place over the cap by the operator, and requires the activation of a start switch on
the handle of the coil assembly to start the sealing operation.

4 Introduction
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Installation 5
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. Figure shows the components of the coil support
assembly.
Figure 1 – Conveyor Coil Support and Components
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 8 on
page 30 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.

6 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.
Figure 2 – Checking that the coil is level
On narrow conveyors, it may be necessary to space the support away from the rear side of the
conveyor.
Hand Held Coil Support
The hand held coil design is made to be held by the operator during the capsealing process. The
bottom of the coil which faces the top of the cap has a small opening which will allow dispenser
style caps to fit inside for proper sealing. Figure 3 on page 7 shows the relationship between the
coil opening and the sealing range of caps to be sealed.
The coil can become quite heavy after continuous usage and may be suspended from a lifting
device of some sort to offset the coil weight and ease operation. Caution must be used to ensure
that no metal components are positioned in the sealing field on the bottom of the coil.

Installation 7
Figure – Hand Held Coil Sealing Range
Inverter
The power supply is supplied in a 0.62" x 6.63" x 5.29" 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.
The power supply can be located in any convenient location within reach of the coil. It is
intended for upright mounting on flat surface. Mounting dimensions are given in Figure 9 on
page 3 .

8 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. The connector (RECP. ) located on the
rear of the power supply cabinet, is provided for attaching either the hand held or the conveyor
coil to the power supply. Note: The power supply is capable of sensing the type of coil attached
to the connector and will automatically update the mode of operation. Optional twenty-foot
cables for the conveyor coil are available upon request.
The power supply is air-cooled and contains a fan to circulate air inside the enclosure. A
minimum of twelve inches clearance should be provided on both sides of the enclosure to ensure
adequate air circulation.
The customer must supply the power supply with single phase input power. 20VAC and
240VAC models are both available from the factory, and a cable and plug are provided for ease
of connection to an appropriate outlet. Fusing and disconnecting means must be provided
according to applicable codes and practices. Full specifications are listed on page 29. Refer to
the connection diagram on page 32 for information about the power-input cable and connection
of the supply voltage.
Cables to the coil are to be routed to the coil support when applicable. The hand held coil is
provided with a cable fixed to the coil, and a connector on the end for attaching to the power
supply cabinet.

Installation 9
Customer alarm or interlock circuitry is also provided and wired to the 0 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. Details on using these interlocks may be found on page .
Conveyor Sealing Coil
There are several different styles of coils available to adapt to various applications. The method
of mounting is the same for all styles. All coils employ a tank capacitor mounted to the top of
the coil.
Note that the coil has an enclosure on top which houses a tank capacitor, cooling fan, and a
connector for attaching the power cable to the coil. Figure on page 5 shows the normal
mounting arrangement. To mount the coil, rotate the clamp lever counterclockwise. 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.
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 4.

10 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. This coil is held by the operator, and requires the
activation of a start switch on the handle of the coil to start the sealing process. A capacitor bank
is enclosed within the coil housing.
Note that the hand held coil has a 0-foot cable permanently attached, with a connector on the
other end going to the power supply. Figure 4 on page 8 shows the normal mounting
arrangement.
Connect the power cable from the coil to the connector on the heatsink on the back of the power
supply. It is very important that the connector is securely fastened and properly positioned.

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.
AC input - The system should be connected to a 20 VAC or 240 VAC, single phase, power
source depending on the model provided. An appropriate cable and plug will be provided from
the factory. Refer to page 32 for the connection diagram.
Customer interlock - These terminals can be used to stop the capsealing 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.
Temperature switch interlock - These terminals are used to monitor the operation of the
cooling fan in the coil. A temperature switch is connected here. If the coil temperature rises
above the normal operating temperature, the capsealing system will turn off. The temperature
switch is a required element of the control circuit and must not be bypassed.
Auto-start - A contact closure across these terminals will enable the auto-start feature. This
feature could be used to put the capsealing system into a standby mode when the conveyor
system stops. When the conveyor starts again, the capsealing system will resume operation
automatically.
When the contacts are closed, the capsealing system will be in a ready condition. The START
button is pressed and the unit runs. If the contacts are opened, the capsealing system will stop
delivering power to the sealing coil, but will not shut off. When the contacts are closed again,
operation will resume, if no fault condition exists.
If the customer interlocks are opened, the capsealing system will shut down completely. To
resume operation, the interlocks must be satisfied, the auto-start contacts closed and the START
button pressed.

12 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.
Run mode monitor - Whenever the capsealing system is running, the run relay will be
energized. A normally open contact is provided.
Use these terminals to monitor the operational mode of the capsealing system.

Installation 3
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14 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. Hand held coils are designed for a variety of cap
styles and sizes. Verify that the cap you are intending to use will fit in the sealing zone shown in
Figure 3 on page 7. If your application does not fit in the usable area, please contact the factory
for additional information.
. The sealing time is displayed on the front panel digital display. Using the Alarm/Timer set
point buttons, adjust the display reading for the proper time. The display is calibrated in
seconds of time with the maximum time setting being ten seconds.
2. Place the coil over the container and cap that you are trying to seal. The cap should be as
close to center under the coil as possible.
3. The switch on the handle of the coil will start the timing sequence when pressed.
4. It is important to note that on larger cap diameters, it may be necessary to adjust the output
power level to a value less than 00%. This is due to the larger mass of foil under the coil,
and the need for additional dwell time, allowing the heat to reach into the center of the cap.
The balance of time versus power will be dependent on the size of the cap, liner material, and
even contents of the container. The power level may be viewed by pressing the Power
Button. The power level may be adjusted using the Power Set Point Up/Down Arrows.