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.

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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

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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

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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

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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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