INDUCTION CAP SEALER SUPER SEAL DELUXE ML OWNERS REFERENCE MANUAL

Transcription

1 INDUCTION CAP SEALER SUPER SEAL DELUXE ML OWNERS REFERENCE MANUAL Enercon Industries Corp. W140 N9572 Fountain Blvd. P.O. Box 773 ( ) Menomonee Falls, WI , USA Phone: (262) Fax: (262) Web Site: Enercon Industries Ltd 64 Edison Road Aylesbury Bucks HP19 8UX, England Tel: Fax Web Site: 6/16/2006

2 Super Seal Deluxe Table of Content SECTION 1 INTRODUCTION...1 SAFETY AND WARNINGS...1 UNDERSTANDING INDUCTION SEALING...2 FOIL WITH PULP BOARD BACKING (Figures 1 & 2)...2 SINGLE PIECE FOILS...2 MATERIAL VARIATIONS...2 INDUCTION CAP SEALER FEATURES (Figure 3)...3 NAMEPLATE AND DECALS (Figure 4)...4 UNPACKING AND INSPECTION...5 SECTION 2 INSTALLATION...6 GENERAL...6 TEMPERATURE...6 ELECTRICAL SERVICE...6 SCREW ADJUSTABLE MOUNT (Figure 5)...6 SCREW ADJUSTABLE MOUNT INSTALLATION DIAGRAM (Figure 6)...7 POWER SUPPLY MOUNTING DIAGRAM (Figure 7)...8 SEALING HEAD INSTALLATION DIAGRAM (Figure 8)...9 BASIC UNIT CABLE PROVISIONS (Figure 9) INSTALLATION-CONTROL PROVISIONS...11 EXTERNAL INTERLOCK...11 LOSS OF SEALING INDICATOR (LSI)...11 SEALING HEAD ALIGNMENT AND ADJUSTMENT...12 FLAT SEALING HEAD (Figure 10)...12 STANDARD TUNNEL SEALING HEAD (Figure 11)...12 DEEP TUNNEL SEALING HEAD (Figure 12) SEALING HEAD (Figure 13) ALIGNMENT TO CONVEYOR (Figure 14)...13 SECTION 3 PRINCIPLES OF OPERATION...14 INTRODUCTION (Figure 15)...14 POWER UP (Figure 16)...14 LED STATUS INDICATORS (Figure 17)...15 VFD DISPLAY (Figure 18)...16 FUNCTIONAL CONTROL KEYS...17 LSI LEVEL ADJUSTMENT SEQUENCE OF OPERATION...18 TIPS FOR DETERMINING CORRECT OUTPUT LEVELS...18 TIPS FOR CHECKING CONTAINER SEALS...19 SECTION 4 MAINTENANCE...20 GENERAL...20 SAFETY PRECAUTIONS, NOTES, CAUTIONS, WARNINGS...20 ROUTINE INSPECTION AND SERVICING...20 VISUAL INSPECTION...20 CONNECTIONS...21 OIL FILLED OUTPUT CAPACITORS w/out BUS BOARD...21 REMOVE/INSTALL OIL FILLED CAPACITORS 2 CAPS (Figure 19)...21 REMOVE/INSTALL OIL FILLED CAPACITORS 4 CAPS (Figure 20) OIL FILLED OUTPUT CAPACITORS w/bus BOARD...22 REMOVE/INSTALL OIL FILLED CAPACITORS (Figure 21) DRY OUTPUT CAPACITORS w/bus BOARD...23 REMOVE/INSTALL DRY OUTPUT CAPACITORS (Figure 22) FANS (Figure 23)...24 QUARTERLY MAINTENANCE...24 SECTION 5 TROUBLESHOOTING...25 TROUBLESHOOTING TABLE...25 SUPER SEAL DELUXE ERROR CODES...26 OHM CHECK FOR BRIDGE RECTIFIER AND INVERTER...27

3 SECTION 7 PARTS LISTS...28 GENERAL...28 DESCRIPTION...28 HOW TO USE THIS PARTS LIST...28 HOW TO ORDER PARTS...28 SHIPPING INSTRUCTIONS FOR RETURNED PARTS...28 SCREW ADJUSTMENT FLOOR MOUNT PARTS BREAKDOWN (Figure 24)...29 MOUNTING BRACKET PARTS BREAKDOWN (Figure 25)...30 STANDARD POWER SUPPLY PARTS BREAKDOWN (Figure 26)...31 CE POWER SUPPLY PARTS BREAKDOWN (Figure 27)...32 INVERTER MODULE AND TEMPERATURE SWITCH PARTS BREAKDOWN (Figure 28)...33 FAN AND SEALING HEAD MOUNTING PARTS BREAKDOWN (Figure 29)...33 VFD DISPLAY (Figure 30)...34 GASKETS (Figure 31)...34 SECTION 8 OPTIONS...35 PORTABLE CART (Figure 32)...35 MOUNT / CART PARTS BREAKDOWN (Figure 33)...36 STACK LIGHT (Figure 34)...37 STACK LIGHT PARTS BREAKDOWN (Figure 35)...38 MOTION / BACK-UP & FOIL MOTION GROUPS...39 MOTION / BACK-UP SENSOR ONLY...39 MOTION / BACK-UP SENSOR CONNECTOR PROVISIONS (Figure 36)...40 MOTION / BACK-UP SENSOR PARTS BREAKDOWN (Figure 37)...41 SENSOR SET UP...42 VFD DISPLAY SENSOR VERIFICATION...43 READY FOR NORMAL OPERATION...43 MOTION / BACK-UP SENSOR REMOVAL...43 FOIL / MOTION GROUP...43 SENSORS...43 MOUNTING BRACKETS...44 BOTTLE COUNTS...44 FOIL / MOTION GROUP CONNECTOR PROVISIONS (Figure 38)...44 FOIL / MOTION GROUP PARTS BREAKDOWN (Figure 39)...45 CAP INSPECTION SYSTEM...46 CAP INSPECTION SYSTEM FUNCTIONS...46 CAP INSPECTION FEATURES...46 BACK UP DETECTION...46 MISSING FOIL DETECTION...46 STALLED BOTTLE DETECTION HIGH CAP DETECTION...47 AUTOMATIC START...47 SENSOR INFORMATION BOTTLE COUNTS...48 JUNCTION BOX...48 SET UP VFD DISPLAY SENSOR VERIFICATION...50 READY FOR NORMAL OPERATION...50 CAP INSPECTION SYSTEM REMOVAL...50 CAP INSPECTION OPTION INSTALLATION DIAGRAM (Figure 40)...51 CAP INSPECTION OPTION PARTS BREAKDOWN TABLE...52 CAP INSPECTION PARTS BREAKDOWN (Figure 41)...53 SECTION 9 MISCELLANEOUS...54 QUARTERLY MAINTENANCE RECORD PRODUCTION INFORMATION NOTES

4 SECTION 1 INTRODUCTION WARNING Please read carefully before installing or servicing. DO NOT OPERATE THIS EQUIPMENT IN A HAZARDOUS ENVIRONMENT! HIGH VOLTAGE is present within this equipment. As with any piece of ELECTRICAL equipment, one should become familiar with the manual furnished before applying power. Proper connections and operation are required for safe use. FOLLOW INSTRUCTIONS for safety of personnel when operating or maintaining this equipment. INSTALLATION of this equipment must be done in accordance with this manual, Enercon installation drawings and local codes to ensure the safety of personnel in the area and in the building. SAFETY AND WARNINGS Before you operate this Induction Cap Sealer, you should take the time to carefully read all the instructions contained in this manual. Electricity and the heating capability have the potential to cause severe personal injury or property damage. Before starting, operating, or making any adjustment identify the components of the Induction Cap Sealer, using this manual as a guide. The operator should use common sense and good working practices while operating and maintaining this unit. Follow all codes and understand the starting and stopping sequence. Check the safety devices following the procedures contained in this manual. *** CAUTION *** CAUTION is used to indicate the presence of a hazard, which will or can cause minor personal injury or property damage if the caution is ignored. *** WARNING *** WARNING is used to indicate the presence of a hazard, which can cause severe personal injury, death, or substantial property damage if the warning is ignored. Maintenance should be done by qualified personnel, adequately equipped with proper tools. Follow the maintenance schedules as outlined in the manual to insure problem free operation after start-up. Safety instructions in this manual are bold-faced for emphasis. The signal words WARNING and CAUTION are used to indicate hazard seriousness levels as follows: 1

5 UNDERSTANDING INDUCTION SEALING Foil with Pulp Board Backing Induction Sealing is a non-contact heating process that accomplishes the hermetic sealing of a container with a closure that includes a heatsealable foil laminate. The typical induction inner seal begins as a multi-laminate liner inside a closure: A) A layer of pulp board. B) A layer of wax. C) Aluminum foil. D) A layer of polymer. A Pulpboard B Wax Absorbed Into Pulpboard Releasing Foil The layer of polymer (D) must be compatible with the container material and capable of heat sealing to the lip of the container. (Figure 1) A Pulpboard B Wax C Foil Figure 1 D Polymer When the closure is placed onto the container and is passed through an electromagnetic field produced by the sealing head, several things occur. An electromagnetic current, called an eddy current, is induced into the foil portion, resulting in a resistance-type heating effect. The heated foil melts the wax layer, which is absorbed into the pulp board, while releasing the foil from it. At the same time the polymer coating melts, hermetically sealing the foil to the lip of the container. When the closure is opened (released) the inner seal is welded to the lip of the container, and the pulp board remains on the inner side of the closure. (Figure 2) C Foil D Polymer Seals Foil To Container Lip Figure 2 Single Piece Foils Unlike the previously mentioned foil with pulp board backing, the liner is laminated with foam or paper backing. When the liner (C) is heated causing the polymer (D) to adhere to the container the entire liner with backing is attached to the mouth of the container. There is no separation of components when the cap is removed. Material Variations Depending on the inner seal material used, this seal can meet the FDA requirements for tamper evident packaging or the seal can provide leakage protection and shelf life extension, often referred to as a freshness seal. Many varieties of inner seal materials have been developed and are available from a number of suppliers. Assistance from the suppliers is available in selecting the proper liner required for the multitude of products and variety of containers. High speeds can be obtained using the process making it well suited for high capacity production lines. 2

6 O OFF ION INDUCTION CAP SEALER FEATURES No. Description No. Description 1 Refer to Section 3 Principles of Operation 4 Sealing Head 2 Refer to Section 2 - Installation 5 Screw Adjustable Mount 3 Rear of Unit STANDARD 1 ene rcon SUPER SEAL - DX 2 CE Figure 3 Features 1 Completely Air Cooled System Electrical Rating: VAC, ± 10%, 1Ø, 10 Amps, 50/60 Hz 240 VAC, ± 10%, 3Ø, 8.7 Amps, 50/60 Hz Compartment Sealed For Nema 4 Rating, Stainless 3 Steel Conveyor Floor Mount Adjustable: 4 Adjustable For Ease of Set Up - Lockable 5 Standard Control Features: START / STOP Output Adjustment / Digital Meter Diagnostics Built Into Display Remote Start Capabilities Can Be Interlocked To Other Equipment Sealing Heads Quick Change PART NUMBER DESCRIPTION CAP SIZE LM COIL 24 to 120mm LM WIDE FLAT 53 to 120mm LM WIDE TUNNEL 28 to 53mm LM NARROW TUNNEL 24 to 38mm CONSULT FACTORY FOR OTHER AVAILABLE HEADS 3

7 OFF O I ON NAMEPLATE AND DECALS This page contains representative examples of the rating plate, nameplates, and decals, which appear on the Induction Cap Sealer. If for some reason an item is defaced, painted over or underlying parts are replaced, we recommend you obtain a replacement from Enercon and reapply it in the location illustrated. STANDARD CE enercon SUPER SEAL - DX Figure 4 4

8 UNPACKING AND INSPECTION Carefully open shipping container and remove the contents. Items should be thoroughly inspected for damage. NOTE: Be extra careful if using a sharp instrument when removing the protective wrapping from the equipment. File a claim with the freight carrier for any damage incurred. Enercon Industries should also be contacted as soon as possible to expedite the shipment of replacement parts. CONTACT: Enercon Customer Service Department Phone Number: (262) Fax Number: (262) Address: info@enerconind.com Website: 24hr Customer Service is available. IMPORTANT: If concealed loss or damage is discovered after delivery, notify your carrier at once and request an inspection. This is absolutely necessary for the carrier to consider your claim. If damage is detected, be sure to note it on freight bill before signing it to acknowledge receipt. The carrier agent should make an inspection and issue a loss or damage report. If you give the carrier a clear receipt for goods that have been damaged or lost in transit, you do so at your own risk and expense. NOTE: The carrier accepts responsibility for this shipment when the carrier signed the bill of lading at the origin of shipment. 5

9 SECTION 2 - INSTALLATION GENERAL NOTE: Check all hardware connections and screws to insure tightness because loosening can occur during shipment. See drawing list supplied with order for your exact equipment. The Enercon Super Seal Deluxe System consists of the power supply cabinet, which includes the attached sealing head. Refer to illustrations in this manual for installing the system. TEMPERATURE The power supply has been designed to operate in a maximum ambient air temperature of 40 C (104 F). ELECTRICAL SERVICE Observe rating plate on the back of the Super Seal Deluxe to verify service requirements before applying power. The Super Seal Deluxe Unit is designed to accept 240 VAC ± 10%, 1Ø or 240 VAC ± 10%, 3Ø, 50/60 hertz. No. Description 1 Wing Screw Locking Knob 2 Screw Adjustable Mount Turn Clockwise To Tighten Or 3 Counter Clockwise To Loosen *** WARNING *** THE POWER SUPPLY SHOULD NOT BE OPERATED WITHOUT THE GROUND PRONG OR GROUND WIRE LINE CORD CONNECTED TO A GROUNDED RECEPTACLE. DO NOT BYPASS THE GROUND TERMINAL. SCREW ADJUSTABLE MOUNT The screw adjustable mount is an assembly used to aid the operator in adjusting the power supply height over the conveyor. With the sealing head centered over the conveyor, the mount assists the operator in obtaining the required gap between sealing head and container to be sealed. Details for these adjustments are covered later in this section. A clamp is located on the side of the mount to aid in maintaining the established height of the mount (Figure 5). A wing screw locking knob is used to tighten or loosen the clamp. The locking knob will need to be loosened to allow adjustment and then tightened once the mount height is correctly set. Figure 5 *** CAUTION *** BE SURE TO LOOSEN THE CLAMP BEFORE ADJUSTING THE SCREW MOUNT. INSURE THAT THE SAFETY NUT LOCATED IN THE BOTTOM TRACK OF THE MOUNT IS IN PLACE WHEN THE POWER SUPPLY IS MOUNTED. OTHER CORNER ALLEN HEAD SCREWS ARE FACTORY SET AND SHOULD NOT BE FIELD ADJUSTED. Units may be ordered with an optional cart for portability. See illustrations provided to show the differences in mounts and associated hardware. 6

10 SCREW ADJUSTABLE MOUNT INSTALLATION DIAGRAM No. Description No. Description 1 Wide spread mount forward. 4 Configuration used for narrow width conveyors. 2 Narrow spread mount back. 5 Slots used for rough adjustment to center sealing head over conveyor. 3 Configuration used for wide width conveyors. 6 Mounting angle (floor) Figure 6 7

11 POWER SUPPLY MOUNTING ILLUSTRATION No. Description No. Description 1 Power Supply 6 Centering Adjustment Position in/out for Centering as required. 2 Base Plate 7 Course Height Adjustment Allows 16 (406mm) of course height adjustment over the 7 (178mm) of Adjustable Mount travel. 3 Screw Adjustable Mount 8 Safety Nut WARNING: Safety nut must be in place when power supply bracket is installed. 4 2 Single nuts for attaching power supply bracket. 5 Power Supply Mounting Bracket Note: Mount Item 6 to Item 4 prior to assembly of Power Supply (Item 2) onto Yoke. Power Supply should be positioned to center sealing head over conveyor Figure 7 8

12 SEALING HEAD INSTALLATION No. Description No. Description 1 Coil Mounting Bracket 4 Sealing Head Connectors - Female 2 Base Plate 5 Sealing Head 3 Sealing Head Connectors - Male 6 Mounting Bolts Figure 8 9

13 BASIC UNIT CABLE PROVISIONS Figure 9 10

14 INSTALLATION-CONTROL PROVISIONS EXTERNAL INTERLOCK The Super Seal Deluxe Power Supply comes standard with provisions for interlocking the control circuits. Two interlock wires must be connected to an isolated normally closed circuit for the unit to start. This closed circuit may be accomplished in a number of different ways but is absolutely necessary for the unit to function properly and be allowed to start. Do not apply any external voltage to these wires. Method 1 As shown in Figure 9, a cable is provided to extend the required interlock wiring to an external contact. These interlock wires share the cord and connector with the remote start wires. Be sure to use only the black and red wires for the interlock circuit, which must be in a normally closed state for the unit to start. The remote start wires, white and green, are associated with the remote start function control key located on the front panel of the unit (See Function Control Keys, page 17). Method 2 A defeat connector is included to provide the required closed circuit for the interlock connection (Figure 9). This simply requires connecting the defeat connector to the back of the unit at the REMOTE START / INTERLOCK connector. The jumper wire inside the defeat connector allows the unit to start without providing an external closed contact. *** WARNING *** ALL NECESSARY PRECAUTIONS SHOULD BE TAKEN WHEN APPLYING AND WIRING THIS CORD TO EXTERNAL CIRCUITRY. THIS LSI JACK WHEN USED BY OTHERS PROVIDES FOR A CONTACT CLOSURE ONLY. PROPER TAG OUT/LOCK OUT PROCEDURES MUST BE FOLLOWED IN REMOVING THIS CORD WHEN CONNECTED TO EXTERNAL CIRCUITS THAT HAVE POWER ON THEM. REMOVE ALL EXTERNAL POWER BEFORE DISCONNECTING CORD. INSURE LOCKOUTS ARE IN PLACE TO PREVENT EXTERNAL CIRCUITS FROM BEING ENERGIZED WHEN THE LSI CORD IS DISCONNECTED. NOTE: Do Not discard the defeat connector. Keep it in a safe place, as it may be required to substitute for method 1, or troubleshooting. LOSS OF SEALING INDICATOR (LSI) As shown in Figure 9, a cable is provided to extend the LSI relay contacts, used for determining the output status of the power supply. A connector, attached to the common (COM), normally open (N.O.) and normally closed (N.C.) contacts of the LSI circuit, is provided on the back of the unit. The cable is connected to the LSI connector and allows for convenient connection of the LSI to external alarm circuitry. These contacts may be wired into an alarm circuit not exceeding 24 volts and 3 amperes. 11

15 ALIGNMENT AND ADJUSTMENT Proper alignment of the sealing head is critical for consistent and repeatable sealing. FLAT SEALING HEAD With the power supply off, install a capped container under both ends of each sealing head. Ensure the containers are at production height. Lower the power supply until a 1/8 (3mm) gap exists between the bottom of the sealing head and the top of the cap (Figure 10). The 1/8 (3mm) gap will allow the highest line speeds with the most consistent seal results. 1 8 " Figure 10 STANDARD TUNNEL SEALING HEAD With the conventional tunnel sealing head, the 1/8 (3mm) gap is established between the top of the tunnel and cap where the cap is inserted into the tunnel (Figure 11). LINER THE LINER MUST BE ALIGNED WITH ALL CENTER LINE LABELS Figure 12 ALIGNMENT AND ADJUSTMENT 1 SEALING HEAD In many instances, multiple cap sizes will be run on the same power supply. The 1 Sealing Head and Pivot Kit allows for moving the sealing head to accommodate various size caps without having to exchange the sealing head. The 1 sealing head can be pivoted in approximately seven (7) degree increments to four different positions (Figure 13). The chart below indicates the desired position for each liner size. The pivot assembly brackets serve to guide the sealing head rotation to provide the proper angle for each liner size shown in the table. The knurled locking knobs serve to lock the sealing head in place. Item # Description mm Position mm Position mm Position mm Position " 3 2 Figure DEEP TUNNEL SEALING HEAD When using a deep tunnel head, the 1/8 (3mm) criteria and gap gauge are not used. Deep tunnel heads have a center line indicator on the top and sides of the tunnel (Figure 12). Some bottle profiles may prevent the foil liner from aligning to these marks. Then the foil should be positioned as far up into the notch as possible, not to exceed the centering marks. CAP (mm) Figure 13 CAP (mm)

16 enercon READY RU N REMOTE AUTO SUPER SEAL - DX Proper alignment of the 1 Sealing Head is critical, use the following steps for proper set up. 1. First align the power supply and sealing head over the conveyor with the sealing head in the #1 position. The mount / cart must be secure. 2. Center the product on the sealing head and ensure that it runs centered along the entire length of the sealing head. 3. Choose the proper position for the caps size to be run and pivot the sealing head to that position, Refer to table below. NOTE: A fundamental requirement for induction cap sealing is to have the proper amount of torque on the cap, which exerts a downward force when sealing. Consult your cap supplier for the recommended torque of your cap. A rule of thumb is to equate half the liner s millimeter size (diameter) to inch-pounds of torque. For example, a 53mm liner would require 27 inch-pounds of torque. NOTE: Check alignment whenever the pivot angle is changed to ensure proper sealing. No tools are required to change the position of the sealing head. Loosen both of the knurled locking knobs, one at each end of the sealing head. Rotate the sealing head to the proper position for the cap size in use. Center the proper indicator line on the locking knobs at each end of the sealing head and hand tighten the locking knobs. ALIGNMENT TO CONVEYOR It is important that each end of the sealing head be equal in height in relationship to the conveyor (Figure 14). Ensure the caps are entering and exiting centered on the sealing head. The higher the liner is in the field, the more heating will occur. Therefore, it is possible to achieve faster rates with CT closures as compared to CR. FRONT VIEW SIDE VIEW enercon SEALING HEAD SEALING HEAD "D" "D" "D" "D" CONVEYOR CONVEYOR NOTE: "D" (DISTANCE) MUST BE EQUAL SIDE TO SIDE AND BACK TO FRONT ABOVE CONVEYOR FOR OPTIMUM PERFORMANCE OF SEALING HEAD. Figure 14 13

17 SECTION 3 PRINCIPLES OF OPERATION Figure 15 INTRODUCTION The Super Seal Deluxe incorporates a control panel that permits simple and direct operator interface (Figure 15). A 2 x 40 Vacuum Fluorescent Display (VFD) is incorporated to display easy to read information. The front panel also includes LED status indicators, START/ STOP and UP/DOWN arrow pushbuttons and function control keys. The LED s indicate the various modes of operation of the sealer. The START/STOP pushbuttons are used to manually start and stop the power supply. The UP/DOWN arrows provide for raising or lowering the output level of the power supply. The arrows permit the raising and lowering of the output level while the unit is running, which is displayed as OUT: on the VFD. The arrows also permit presetting the output level before the unit is started, displayed as SET: on the VFD display, as well being used in conjunction with the function control keys for programming. The current output level will have its set point retained on the display as the SET: level once the unit is stopped. The six function control keys are used to control and monitor the power supply s basic and optional features. These are described in more detail on page 17 of this section. 1. LED Status Indicators 2. Vacuum Fluorescent Display (VFD) 3. Function Control Keys 4. START/STOP and UP/DOWN Control Figure 16 POWER UP Before attempting to start the power supply, verify that the Super Seal Deluxe has been properly installed as outlined in earlier sections of the manual. In particular, it will be necessary to verify that interlock circuits are satisfied. The unit can be initially started in its basic mode by using the defeat connector as described in the installation section of the manual. Interlock circuits must be satisfied for the unit to start. Immediately after the breaker is turned on, a title screen will briefly appear on the VFD display. The title screen will indicate Super Seal Deluxe on the left side and the software version installed in the unit to the right (Figure 16). The title screen is replaced by the main operator screen which displays the output monitor and status messages for normal operation (Figure 15). 14

18 LED STATUS INDICATORS Ready Indicates power is applied and unit ready for start up. No critical system errors are present. Run Indicates the system has been started and is operational for sealing. The OUT: display will change from 0% to the same level as the % as SET: on display. No faults may exist to be in the Run mode of operation. Remote This LED is an indication that the unit has been conditioned to be started by an outside command. It is necessary to use the remote start cable that is furnished and have it connected for the incoming start command. It will also be required to satisfy the interlock circuit supplied with this same cable. The STOP STOP pushbutton should be pressed for START reset and the START pushbutton pressed to activate or prime the system in order to receive an outside start command. Any fault commands will require clearing the fault, resetting the logic with a stop command, then a new prime command, using START the pushbutton in order to receive additional remote start signals. Auto Auto is an indication that the output % level is to be controlled from an outside 0-10 VDC signal. This mode of operation is seldom used and must be ordered from the factory with the original equipment AUTO order. The pushbutton is used to change from the normal output level controls, using the arrow indicators, to the required 0-10 VDC signal. Figure 17 15

19 Figure 18 VFD DISPLAY The operator Screen displays useful information on system status (Figure 18). The first line is the Output Monitor and displays the current set point and the actual output. The right portion of the VFD is the Setup and Options Display and displays setup information in setup mode and Foil/Motion group or Cap Inspection information in normal operation, when included with system. Just below the monitor is a variable message area referred to as the Status Message Box. Stopped Indicates the unit has no output. Running Indicates there are no faults and the unit is started and has output. Inverter Fault Indicates the unit experienced a power device fault (It may be best to consult with customer service before attempting to restart). Stalled Bottle Fault Indicates the Cap Inspection System reported a stalled bottle condition. Temperature Fault Indicates the device heat sink (base plate) is getting too hot (Check the rooms ambient temperature, cleanliness and proper operation of all the cooling fans). Interlock Fault Indicates an interlock is open. properly. (This is the only system error without an error code.) Missing Foil (Optional Message) this is displayed only temporarily whenever the Cap Inspection System reports a missing foil. High Cap (Optional Message) this is displayed only temporarily whenever the Cap Inspection System reports a high cap. If more than one fault occurs they will be displayed one at a time in the Status box. Note: A system error message, especially a consistent one, almost always means service is required. The only potentially benign system error is #99. The operator would get this error if he pressed more than one button at a time. Both system errors and critical faults stop the unit, if running, and require the operator to press the STOP pushbutton to reset them. The operator should note the code and report any system errors, whether infrequent or consistent. Over Current Trip Indicates the output current exceeded the maximum allowed peak. System Error Indicates the system itself has experienced an internal error. An error code is displayed along with the System Error message. Refer to the error codes table, Section 5 troubleshooting, to identify what any error messages represent. Communication Error Indicates the display and the system control boards are not communicating 16

20 FUNCTION CONTROL KEYS AUTO Auto The AUTO function is only used when it is desired to externally control the output % level of the power supply. Pressing the Auto pushbutton allows switching between manual and auto modes of operation. The AUTO LED will be lit when the unit is in auto operations mode. The control panel's Up/Down arrows will not function, and an isolated 0-10VDC signal must be supplied via the cable connected to the process interface port. REMOTE Remote The REMOTE function is used to transfer the start command from the local control panel to an external source. Pressing the Remote pushbutton toggles between local and remote modes of operation. The REMOTE LED will be lit when the unit is in remote operations mode. When using the remote start feature, it is necessary to connect the supplied REMOTE START/INTERLOCK cable to the connector located on the back panel. The remote start wires share the cord and connector with the interlock wires. Be sure to use only the white and green wires to connect to the remote start contact, which must be closed for the unit to start and open to stop. The black and red wires are associated with the interlocks. Since this cable replaces the defeat connector it is necessary to provide a closed interlock contact, or a jumper, between the interlock wires for the unit to start. SETUP Setup The SETUP function enables the setup mode and allows information to be input or changed. The setup information is viewed on the right portion of the VFD display (See Figure 18). For a basic system, the right portion of the screen will normally be blank when the system is operating. When the system incorporates the Optional Foil/Motion group or Cap Inspection System, this portion of the VFD display is used to show information of these options during normal operation. Refer to SECTION 8 OPTIONS for more detailed information. SELECT SCROLL DONE Setup Function When the SETUP function is enabled SCROLL DONE the SELECT, and pushbuttons are used to program certain features of the power supply and options. The setup information will be displayed on the Setup and Options Display. The Status Message Box will also display information to assist in the programming setup. For the basic system, the four function key pushbuttons are only used to set the LSI (Loss of Seal Indication). The LSI feature, standard on Enercon power supplies, is used to establish a minimum % output threshold. Once set, if the output is brought below the established threshold level, the control is made to detect this condition. A cable supplied with the system may be connected to external control circuits to provide a signal for indicating that the minimum operating level has been exceeded. Dry relay contacts (N.O. and N.C.) are provided. It is recommended that the user limit his control voltage to 24 VDC 3 amps. LSI LEVEL ADJUSTMENT The LSI detection level is set to 60% during the testing phase of the equipment. You will be able to adjust the LSI set point to any level you desire through the output range of the unit. To set the LSI detection level, the following programming steps are to be followed. This should only be done after establishing the operational output level required for the line. If more than one level of output level is used on a process line, it will be necessary to reset the LSI level each time the output level is changed. Experience will dictate the desired spread between the operating output level and LSI threshold but for illustration purposes, 5% will be used. The unit should be stopped for this adjustment, although not necessary. Observe the operating set point, i.e. 90%. Press the SELECT pushbutton. FUNCTION LSI LEVEL should be displayed on the right side of the VFD display. Note: SCROLL Pressing the pushbutton will toggle between OPTIONAL CAP INSPECTION message 17

21 and LSI LEVEL status. Leave in the LSI Level mode. SELECT Press the pushbutton and observe that LSI LEVEL and a % level are displayed. The message screen should also display (Adjust: (+/-) Save (Done). Use the UP/DOWN arrows to change the set point level. For the example of 90% output used, the LSI level is changed to 85% with the arrows. As mentioned earlier, the actual operating conditions may dictate a narrower set point. Press the DONE pushbutton when the previous step is completed. The message will return to the second step above. Press the DONE pushbutton a second time to extinguish the set up and return to normal operation. This completes the set up for the basic system. The unit should be ready to be placed into production at this point. SEQUENCE OF OPERATION Interlock Satisfaction: Insure interlocks has been satisfied as previously described in the Installation and Principles of Operation Section. Power Up: Place Circuit Breaker / Power Switch into the ON position. The READY status light should be lit with the VFD display indicating a STOPPED condition and the preset percentage of output. If in REMOTE, it also will be energized. Remote requires provisions for an external maintained contact start command. Press the START pushbutton in order to enable the remote start function. If the interlocks are opened or the Circuit Breaker / Power Switch is turned off and then back on it will require that the START pushbutton be pressed again. Note: Once remote has been selected, indicated by the remote status LED being lit, it will not be possible to change from remote back to local without pressing the STOP pushbutton. START Start Up: Press the START pushbutton to start the induction sealer. Output (sealing) power is now initiated. The STOPPED message will change to RUNNING. The OUT: message on the VFD display will change from 0% to the same value as the preset percentage of output percentage. If in 18 remote mode of operation, the external start command must be delivered for the above to occur. Return to Stop: When operating from the local panel, merely press the red STOP pushbutton to return to a stopped condition. With the remote mode of operation, opening the start command or pressing the power supply stop pushbutton will return to the stopped condition. TIPS FOR DETERMINING CORRECT OUTPUT LEVELS Sealing Head Alignment: Insure sealing head is aligned correctly. Bottle Quality: Insure land of the bottle top (seal point on bottle) is reasonably free of burrs, seams, etc. Torque Requirements: Insure caps are properly torqued. Typical requirements are listed in the following table. Cap Size Torque Cap Size Torque 15mm 18mm 20mm 22mm 24mm 28mm 33mm 38mm 43mm 48mm 6-9 in./lbs.68-1nm 7-10 in./lbs nm 8-12 in./lbs nm 9-14 in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm 53mm 58mm 63mm 70mm 83mm 89mm 100mm 110mm 120mm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm in./lbs nm Operating Output Level: Start at a moderate output setting. Run a single container underneath the sealing head. Check the bottle for a seal. Did it seal at all? If it partially sealed, use a new bottle and see next paragraph. If it didn t, repeat the test with a 10% meter increase until the container seals. Refine the setting with a 1-2% adjustment until desired seals are achieved. Position and run a tightly grouped number of containers in-line which completely occupies the full length underneath the sealing head. This will test the power load requirements for a maximum

22 loading situation using these containers. Verify the output % reads constant when performing this test. Record output setting, line speed, sealing head gap, and cap type for future reference. Do this for the various types of caps and containers. TIPS FOR CHECKING CONTAINER SEALS Due to the wide variety of sealing materials available, particular adhesion properties will have to be determined by the customer. Generally, proper sealing can usually be determined by the following questions. SEAL TROUBLESHOOTING TABLE Symptom Probable Cause Possible Solution Partial seal, weak seal, no seal. Seal extremely difficult to remove (1- piece liner). Cap extremely difficult to remove (2- piece liner). Burnt Cardboard Liner. Low removal torque, no removal torque. Pin holing. Pinwheel effect on liner. a. Insufficient power from sealer, conveyor too fast, or power set too low. b. Improper coil height. c. Insufficient application torque. d. Induction liner incompatible with the bottle material. e. Bottle neck finish has been flame/chemically treated. f. Imperfections in container finish, land area. a. Power from sealer set too high. b. Conveyor speed is set too slow. a. Insufficient wax melt, conveyor speed too fast, or output power set too low. b. Improper coil height (too high). c. Excessive application torque. d. Foam liner material welds to polymer in induction liner. a. Excessive power from sealer, conveyor too slow, or power set too high. b. Bottles back up under sealing head. c. Insufficient application torque. d. Gap between liner and container lip caused by defect in container. a. Insufficient application torque, closure not securely applied. b. Excessive application torque, threads of closure stripped. c. Void created when wax is absorbed into pulpboard. a. Excessive power from sealer, conveyor too slow, or power set too high. b. Product may be attacking liner, if pinholes occur well after a good seal has been confirmed. a. Retorquing too soon after induction sealer. b. Wax was not absorbed into pulpboard completely. a. See Page 15 for Determining Output Level. b. See Page 11 for Sealing Head Alignment. c. Check for proper Application Torque. d. Contact your supplier, or send samples for testing. e. Contact your supplier. f. Contact your supplier a. See Page 15 for Determining Output Level. b. Ensure line speed is correct. See Page 15 for Determining Output Level. a. See Page 15 for Determining Output Level. b. Page 11 for Sealing Head Alignment. c. Check for proper Application Torque. d. Material in cap and backing material in liner may be too compatible contact your supplier. a. See Page 15 for Determining Output Level. b. See page 11 for Sealing Head Alignment., check for cocked cap. Do not stop conveyor while unit is still running. c. Check for proper Application Torque. d. Contact your supplier. a. Check for proper Application Torque. b.check for proper Application Torque. c.contact your Sales Manager to discuss possible solutions. a. See Page 15 for Determining Output Level. b. Contact your supplier or send samples for testing. a. Move Retorquing equipment further down stream of sealer. b.see Page 15 for Determining Output Level. 19

23 SECTION 4 MAINTENANCE GENERAL The Enercon Super Seal Deluxe Induction Cap Sealer System is designed to require minimal maintenance. However, to insure long-range reliability, it is a good practice to have a planned maintenance program. This section will include recommended preventative and corrective maintenance procedures. SAFETY, PRECAUTIONS, NOTES, CAUTIONS, WARNINGS Warning: The use of high voltage is necessarily employed in the operation of this equipment. Precautions have been taken in the design of this equipment to make it as safe as possible for both operator and service personnel. However, since no amount of interlocks and safety devices can be absolutely infallible, precautionary measures must always be taken when working on this equipment. Lockout: Use proper lockout and tag out procedures prior to removing any covers, panels, or cords provided for access. Insure power cannot be applied before entering. Use safety as the first step. Keep away from live circuits: Do not reach into the equipment or any electrical enclosure without first removing the power. Never apply power to the unit without the cover on and securely in place. Observe extreme caution when servicing equipment: Do not connect any foreign apparatus external to the system enclosure to Circuits internal to the equipment. Connecting the apparatus in this manner, in addition to being a great hazard can also cause failure to the equipment itself. Input and output cables are provided with this equipment for external use including its options. Do not tamper with interlocks: Under no circumstances should any safety interlocks be defeated nor should any of the safety devices be relied upon for removal of voltage from the equipment. Familiarize yourself thoroughly with the equipment: Never attempt to work on this equipment unless you are completely familiar with it. Never assume that a circuit is dead. MAKE SURE!!! Always wear protective eyeglasses while working within the enclosure. Do not stand in water or on grounded surfaces or touch ground surfaces while reaching in any system enclosure. A thick piece of wood or other insulating material will act as an additional grounding barrier. Capacitors store charge: Never trust a capacitor to be bled off completely. A meter or ground strap should be used to check each stud or lead before handling. Some capacitor studs, including those not tied to bus work (not used), may build up a considerable static charge. GROUND BEFORE HANDLING! ROUTINE INSPECTION AND SERVICING The Enercon Induction Cap Sealer Power Supplies are designed to survive the rugged use that may be imposed upon them under rough environments. However, preventative maintenance can play an important role for long life and durability of equipment if preventative maintenance steps are followed: *** WARNING *** BE SURE ALL POWER IS DISCONNECTED AND LOCKED OUT FROM UNIT BEFORE PERFORMING ANY PREVENTATIVE MAINTENANCE PROCEDURES. Visual Inspection A periodic visual inspection is good practice. One should check for dust build-up, etc., that is detrimental to the equipment. An air hose is convenient for removing dust that may have accumulated. NOTE: The power supply is in a sealed enclosure and should not accumulate foreign matter. The sealing head located under the unit can be inspected by removing the hardware supporting them on each end. The head can weigh over ten pounds and has electrical connections attached. Use caution and support blocks when removing the sealing head. Avoid dropping the sealing head as external or internal damage may occur. 20

24 Connections Power and bus connections should remain tight. Loose connections may be recognized by discoloration of the bus work or parts. If the cover is removed, it affords an opportunity to check connections. Over-torque of connections needs to be avoided. Oil Filled Output Capacitors w/out Bus Board The output capacitors are located inside of the power supply in 1 bank of 2 or 4 capacitors. Remove the power supply cover and visually inspect the capacitors for swelling or oil leakage as well as loose or overheated connections. To measure the capacitors with an ohm meter, disconnect one of the 2 output cables and ohm across each of the capacitors in each bank (Figures 19 & 20), a short is the most typical failure reading. If any of the capacitors is swollen, leaking or measures shorted you will need to replace all capacitors in that bank. The following steps should be followed to replace the capacitors. Remove/Install Oil Filled Capacitors 2 Caps 1. Remove the jumper and output cables (2 & 3) and bus bar (4) from the capacitors (1) in the affected bank by removing the nuts (5) on the capacitor studs (Figure 19). 4. Install the bus bar (4) onto the pair of new capacitors but DO NOT tighten the nuts at this time. 5. Place the new capacitors onto the power supply base plate and ensure the lips of the capacitors are in the trough (9) in the base plate. Ensure the replacement gasket material (10) is on each capacitor. 6. Slide the mounting plate onto the holding screws (7) and onto the capacitors. Tighten the acorn nuts until the gasket material just begins to compress. 7. Tighten the nuts on the capacitors studs to 20 in. lbs and reinstall the fan power wires. Remove/Install Oil Filled Capacitors 4 Caps 1. Remove the output cables (2) and bus bars (3 & 4) from the capacitors (1) in the affected bank by removing the nuts (5) on the capacitor studs (Figure 20) Figure Remove the fan power wires (11) and the acorn nuts (6) from the mounting plate holding screws (7). Then remove the mounting plate (8) and capacitors. 3. Ensure the mounting location is clean and free of oil residue. Also ensure the Nomex insulator is still in good shape. Clean the mounting location and replace the insulator as needed Figure Remove the fan power wires (13) acorn nuts (6) from the mounting plate holding screws (7). Then remove the top mounting plate (8) and top 2 capacitors. 3. Remove the holding screws (10) from the bottom mounting plate (9) and remove the bottom pair of capacitors. 4. Ensure the mounting location is clean and free of oil residue. Also ensure the Nomex insulator is still in good shape. Clean the mounting location and replace the insulator as needed.

25 5. Install the horizontal bus bars (3) onto each pair of new capacitors but DO NOT tighten the nuts at this time. 6. Place the new bottom capacitors onto the power supply base plate with the screw holes exposed between the capacitors and ensure the lips of the capacitors are in the trough (11) in the base plate. Ensure the replacement gasket material (12) is on each new capacitor. 7. Install the bottom mounting plate onto the capacitors and install the holding screws (10). Tighten the holding screws to the mounting plate until the gasket material just begins to compress. 8. Place the new top capacitors onto the bottom mounting plate with the holding screws (7) between the capacitors. Ensure the replacement gasket material (12) is on each new capacitor. 9. Install the vertical bus bars (4) and output cables (2) onto the capacitors but DO NOT tighten the nuts at this time. 10. Install the acorn nuts onto the holding screws and tighten until the gasket material just begins to compress. 11. Tighten the nuts on the capacitors studs to 20 in. lbs and reinstall the fan power wires. proper location on the board, and remove the fan wire (10). 2. Loosen the holding bolts (6) to allow removal of the capacitor tank bus board (7) and the fan (11) and fan mounting bracket (12). *The jumper is only installed on the 2 capacitor bank. Note: When the bus board is reinstalled ensure the direction of each feedback jumper cable is correct through the CT (8) as well as the proper location of the control wires and output cables. 3. Remove the capacitors from the mounting bracket (10). 4. Ensure the mounting location is clean and free of oil residue. Clean the mounting location and replace the Nomex insulator as needed. 1 4 CAPACITOR BANK DO NOT OVER TIGHTEN any of the nuts on the capacitor studs, holding screws or the acorn nuts as damage may occur to the capacitors Oil Filled Output Capacitors w/bus Board The output capacitors are located inside of the power supply in a bank of either 2 or 4 capacitors. Remove the power supply cover and visually inspect the capacitors for swelling or oil leakage as well as loose or overheated connections. To measure the capacitors with an ohm meter, disconnect the output cable (2) and ohm across each of the capacitors in each bank (Figure 21), a short is the most typical failure reading. If any of the capacitors is swollen, leaking or measures shorted you will need to replace all capacitors in that bank. The following steps should be followed to replace the capacitors CAPACITOR BANK Remove/Install Capacitors 1. Remove the output cables and jumper wire* (2) and the feedback jumpers (3 & 4) from the capacitors (1) in the affected bank by removing the nuts (5) on the capacitor studs and note the cable locations on the capacitors. Remove the control wires (9) from the board and note their Figure 21

26 5. Place the capacitor tank bus board onto the new output capacitors. Install the nuts to the capacitor stud leaving the studs that the cables attached to empty. For the 2 capacitor bank install the jumper wire and place the nuts on those 2 studs to secure the board to the Capacitors. Snug the nuts to the board, but DO NOT tighten them at this time. 6. Install the capacitor bank into the mounting bracket and align the capacitors so the lip of the bottom capacitors rests in the trough (14) in the base plate. 7. Install the holding bolts into the fan mounting bracket, w/fan attached, and then install the bolts and bracket onto the capacitor mounting bracket. Snug the holding bolts on the mounting bracket ensuring the capacitor tank bus board is held in place, but do not tighten at this time. 8. Reinstall the output cable, feedback jumper cables, fan wires, and control wires to their proper locations on the capacitors and bus board. On the 2 capacitor back remove the nut already installed to install the output cable. 9. Tighten the holding bolts until the lock washer compresses and then tighten the nuts on the capacitors studs to 20 in. lbs. DO NOT OVER TIGHTEN any of the nuts on the capacitor studs or the holding bolts as damage may occur to the capacitors. Dry Output Capacitors w/bus Board The output capacitors are located inside of the power supply in a bank of either 2 or 4 capacitors. Remove the power supply cover and visually inspect the capacitors for damage as well as loose or overheated connections. To measure the capacitors with an ohm meter, disconnect the output cable (2) and ohm across each of the capacitors in each bank (Figure 22), a short is the most typical failure reading. If any of the capacitors is damaged or measures shorted you will need to replace all capacitors in the bank. The following steps should be followed to replace the capacitors. Removing/Installing Output Capacitors 1. Remove the output cables and jumper wire* (2) and the feedback jumpers (3 & 4) from the capacitors (1) by removing the connector bolts (5) securing the board to the capacitors. Note the cable locations on the capacitors. 2. Loosen the holding bolts (6) to allow removal of the capacitors from beneath the capacitor tank bus board (7). The holding bolt supports (9) will 23 hold the board so that complete removal should not be required. 3. Ensure the mounting surface is clean. Clean the mounting surface as needed CAP BANK 1 SIDE VIEW TOP VIEW 5 2 CAP BANK 1 SIDE VIEW TOP VIEW Figure 22 *The jumper is only installed on the 2 capacitor bank. Note: When the capacitor tank bus board is reinstalled ensure the direction of each feedback jumper cable is correct through the CT (8) as well as the proper location of the control wires and output cables

27 4. Place the new capacitors beneath the tank bus board and align the capacitor connector bar holes with the holes in the board. 5. Reinstall the output and jumper cables (2, 3 & 4) to their proper locations and install and snug the connector bolts in place. 6. Tighten the holding bolts (6) down and then tighten the connector bolts (5) ensuring the tank bus board is secure to the capacitors and that the entire assembly does not move. Fans The fans, located on the bottom of the unit, cool the power supply and sealing head. Two fans are employed, blowing air in opposite directions (Figure 23). One blows air onto the base of the power supply, the other directs airflow onto the sealing head. NOTE: One should ensure that both fans are functioning when doing maintenance. Some applications apply the Super Seal in a wash down environment. Your Super Seal power supply is built with external wash down fans. In order for the fans to operate properly in a wet environment they must remain running. Allowing the fan to stop while wet will increase the chance of it seizing. AIR FLOW DIRECTION OUT IN Figure 23 Quarterly Maintenance Refer to Section 8 for the Quarterly Maintenance requirements of this equipment. Record results as required. 24

28 SECTION 5 TROUBLESHOOTING The Enercon Super Seal Deluxe Induction Cap Sealer is designed for reliable and trouble-free operation. If a failure should occur, the following table is provided in order to save time and expense to both the customer and manufacturer and aid a quick resolution of the problem. Contact Customer Service with any questions. SYMPTOM STATUS indicators VFD display do not light up, nothing happens READY indicator lit, but dim READY indicator on, VFD output % does not change with start command. OUTPUT fluctuations (greater than 2%) INVERTER fault message on VFD TEMPERATURE fault message on VFD OVER current trip message on VFD. TROUBLESHOOTING TABLE PROBABLE CHECKS TO MAKE Circuit Breaker / Power Switch off check breaker / switch No power from utility check incoming voltage Incorrect input power verify correct voltage is supplied Ribbon cable loose (inside power supply) Display or control board failure (inside power supply) Input power wrong. Control board failure. Unit in remote, remote status light on, requires remote start command Display indicates interlock fault message. Customer interlocks open defeat connector missing VFD Loose connections Failed devices, observe fault message on VFD Sealing head failure or capacitor failure Note: Capacitors internal to power supply, disconnect leads when ohm checking Board failure Line voltage varies Unit coupling with metal in vicinity causing overload Sealing head connections loose Control board failure Power device failure. Check IGBT Control board failure Base plate too hot - check ambient, cleanliness Cooling fan stopped Loose connections on temp sensor or board Output current exceeded allowed level Line voltage or control board problem INTERLOCK fault message on VFD Interlock circuit is open, must be closed to start System has experienced an internal error. An error code SYSTEM error message on VFD is displayed consult factory. Control logic board and display are not communicating COMMUNICATION error message on VFD properly check connections, consult factory. NOTE: System errors and faults will stop the unit requiring the operator to press the STOP pushbutton to clear them. Enercon Customer Service Department Phone Number: (262) Fax Number: (262) Address: info@enerconind.com Website: 24hr Customer Service is available. 25

29 Super Seal Deluxe Error Codes Code # Explanation Possible Causes 1 4 FPGA Verification Error EEPROM Verification Error U13 (SPROM) Bad or Missing Bad/Shorted Connection on Interface buss (INTFCE0-7) Bad/Shorted Connection on traces between FPGA and U13 R41 (0 ohm) mode resistor missing/bad connection U7 (EEPROM) Bad or Missing Bad/Shorted Connection on I 2 C interface between U3 and U7 5 Configuration Error Fresh EEPROM (Parameters not previously stored in EEPROM) Invalid Parameter Setting ( Parameter set to default value ) 6 FPGA Query Error 8 Query RS485 Error 9 Broadcast Error 10 Query Display Error 11 Update Display Error 12 Query Inspection Error 13 EEPROM Save Error 99 Keyboard Error Bad/Shorted Connection on Interface buss (INTFCE0-7) Bad/Shorted Connection on traces between FPGA and U13 Brown Out or Excessive Noise (check noise factors) RS485 micro bad/missing (dip switch set to enable RS485?) Bad/Shorted Connection on Interface buss (RB0-7) or U1-0,2 Brown Out or Excessive Noise (check noise factors) RS485 micro bad/missing (dip switch set to enable RS485?) INSP micro bad/missing (dip switch set to enable INSP?) Bad/Shorted Connection on Interface buss (RB0-7) or U1-0,2 (U2-0,2) Brown Out or Excessive Noise (check noise factors) Bad connection to display via ribbon cable Check interface circuitry on both boards Bad connection to display via ribbon cable Check interface circuitry on both boards Bad Phase or insufficient Dead Time INSP micro bad/missing (dip switch set to enable INSP?) Bad/Shorted Connection on Interface buss (RB0-7) or U2-0,2 Brown Out or Excessive Noise (check noise factors) (Save occurs at power loss this error should never be displayed) U7 (EEPROM) Bad or Missing Bad/Shorted Connection on I 2 C interface between U3 and U7 Two or more buttons have been pressed simultaneously Bad/Shorted Connection between DISP and pushbuttons 26

30 OHM CHECKS FOR BRIDGE RECTIFIER AND INVERTER Checking for failed Bridge Rectifier and Inverter Transistor. Any Zero ohm reading will constitute a bad Semi-Conductor. Gate leads must be replaced with devices. Meter Required: Standard Analog VOM -OR- DVOM with Diode Test ***IMPORTANT*** 1. REPLACE the gate leads with the device. 2. Apply an EXTREMELY thin film of thermal compound to the base of the device before mounting it to the heat sink. Apply a dab of thermal compound to the center of the base of the device and spread the compound around the entire surface of the device. Wipe away any excess, too much can be detrimental, and cause device failure. 3. Securely mount the device, the heat sink and torque the connections to 30 inch-pounds or 3.39 N-m. BRIDGE RECTIFIER *** WARNING *** BE SURE ALL POWER IS DISCONNECTED AND LOCKED OUT FROM UNIT BEFORE PERFORMING OHM CHECK. RECTIFIER CHECKS METER HOOK-UP VOM (RX1 SCALE) DVOM (DIODE TEST) A to C, A to D (+)A/(-)C,(-)D & (-)E OPEN OPEN A to E (-)A/(+)C,(+)D & (+)E 10.4V B to C, B to D, (+)B/(-)C,(-)D & (-)E 10.4V B to E (-)B/(+)C,(+)D & (+)E OPEN OPEN INVERTER METER HOOK-UP VOM (Rx1 SCALE) DVOM (DIODE TEST) (+)A to (-)B OPEN OPEN (-)A to (+)B 20.4V (+)A to (-)C 20.4V (-)A to (+)C OPEN OPEN (+)B to (-)C 40.8V (-)B to (+)C OPEN OPEN *(+)D to (-)E Slight Deflection, Then OPEN OPEN *(+)G to (-)F Slight Deflection, Then OPEN OPEN *Use Highest Resistance Scale and Measure with Gate Leads Disconnected (+) Positive Meter Lead (-) Negative Meter Lead 27

31 SECTION 6 PARTS LISTS GENERAL This section, which contains illustrated parts breakdowns, has been prepared as an aide in identifying and ordering parts for the Induction Cap Sealer. All of the items listed in the parts breakdown are manufactured with the same precision as the original equipment. The parts breakdowns illustrate the various assemblies, sub-assemblies, and detailed parts that make up the Induction Cap Sealer and Standard Accessories. A series of illustrations show each part clearly and in its correct location relative to the other parts in the illustration. The Part Numbers, Descriptions, and Quantities used are listed in numerical order on the same page as the diagrams. HOW TO USE THIS PARTS LIST Refer to the following pages to locate the desired illustration. Locate the part on the illustration by visual identification, Part Number, and description from the Parts Breakdown Table. HOW TO ORDER PARTS In order that all avoidable errors are eliminated when ordering parts, please specify the following: The Model Number of the unit as shown on the Cap Sealer Rating Plate (See Figure 4, Page 4). The Serial Number of the unit as shown on the Cap Sealer Rating Plate (See Figure 4, Page 4). The Part Number and Description as listed on the parts breakdown diagrams, and quantity needed. To order parts contact: Ensure both shipper and receiver address is clearly printed on top of package along with the Return Control Number. Parts must be sent PREPAID to: Enercon Industries Corporation W140 N9572 Fountain Blvd. Menomonee Falls, WI NOTE: When returning the Cap Sealer, make sure it is in an upright position and indicated on carton. Enercon Customer Service Department Phone Number: (262) Fax Number: (262) Address: info@enerconind.com Website: 24hr Customer Service is available. SHIPPING INSTRUCTIONS FOR RETURNED PARTS Before shipping parts back, contact Enercon Customer Service Department for a Return Control Number (RCN). If possible use the original packaging material or use a fiberboard box using adequate packaging materials such as Styrofoam peanuts, bubbles, etc. 28

32 SCREW ADJUSTMENT FLOOR MOUNT PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 LM Screw Adjustable Mount (Entire Assembly w/brackets) 1 2 FD Hand Wheel 1 3 FD Extension Bracket 2 4 FD Mounting Bracket 2 5 FD Floor Mount Angle 2 6 HW0041 Wing Screw 1 7 MS2501 M8 10mm Stainless Steel Set Screw 1 8 FD M8 Nut 9 9 MS2457 M8 x 25mm Long Stainless Steel 4 10 WA1630 M8 Lock Washer - Stainless Steel WA4090 M8 Flat Washer Stainless Steel 4 12 MS2467 M8 x 20mm Long Stainless Steel 4 13 MS2466 M8 x 16mm Long Stainless Steel 4 14 MS1555 5/16 18 x 1-1/2 (38.1mm) Large Stainless Steel 4 15 NU2060 5/16 18 Stainless Steel Nut 4 16 WA1600 5/16 Lock Washer Stainless Steel 4 17 NA (457.2mm) Guide Rule Label Figure 24 29

33 MOUNTING BRACKET PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 MS2451 M6 x 16 Socket Head Screw Stainless Steel 4 2 WA1620 M6 Lock Washer Stainless Steel 4 3 FD Mount Angle L.H. 1 4 FD Mount Bar 1 5 FD Mount R.H. 1 6 WA2201 M6 Flat Washer - Stainless Steel 4 7 FD M8 Nut - Stainless Steel 2 8 MS2457 M8 x 25 Socket Head Cap Screw - Stainless Steel 4 9 MS2467 M8 x 20 Socket Head Cap Screw - Stainless Steel 2 10 WA1630 M8 Stainless Steel FIGURE 25 30

34 STANDARD POWER SUPPLY PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 LM Super Seal Deluxe Control Board 1 2 LM Super Seal Deluxe Power Board 1 3 BR0013 Bridge Rectifier 1 4A CP2632 Oil Filled Capacitor, M.F. or H.F./H.V. Output* 2 / 4 4B CP2634 Oil Filled Capacitor H.F. Output* 2 5 CP2636 Dry Capacitor, M.F. or H.F./H.V.* 2 / 4 6A CB0175 Circuit Breaker, 20A, 250V-2 Pole (Not Shown) 1 6B CB0245 Circuit Breaker, 15A, 250V-3 Pole (Shown) 1 7 LM Output Transformer Assembly 1 8 FA0081 Fan, 27 CFM 1 9 LM Connection Assembly 1 10 LM Capacitor Bus Board used w/dry Capacitor Bank 1 11 LM Capacitor Bus Board used w/oil Filled Capacitor Bank 1 *Determined by sealing head and application 6A, B A 4B 11 Figure 26 31

35 CE POWER SUPPLY PARTS BREAKDOWN ITEM # PART NO. DESCRIPTION QTY. 1 LM Super Seal Deluxe Control Board 1 2 LM Super Seal Deluxe Power Board 1 3 BR0013 Bridge Rectifier 1 4A CP2632 Oil Filled Capacitor, M.F. or H.F./H.V. Output* 2 / 4 4B CP2634 Oil Filled Capacitor H.F. Output* 2 5 CP2636 Dry Capacitor, M.F. or H.F./H.V.* 2 / 4 6 SW0191 Main Power Switch 20A, 250V 2 Pole 1 7 LM Output Transformer Assembly 1 8 FA0081 Fan, 27 CFM 1 9 LM Connection Assembly 1 10 LM Capacitor Bus Board used w/dry Capacitor Bank 1 11 LM Capacitor Bus Board used w/oil Filled Capacitor Bank 1 12 EM0080 Power Line Filter 1 13 FU0124 Fuse 2A, 250V 1 14 CB0050 Thermal Over current Circuit Breaker 20A, 250V 1 *Determined by sealing head and application B 9 4A Figure

36 INVERTER MODULE AND TEMPERATURE SWITCH PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 LM Inverter Module 1 2 SE0158 Temperature Switch 1 Note: Parts shown with boards removed from power supply. 1 2 Figure 28 FAN AND SEALING HEAD MOUNTING PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 FA0024 Fan 2 2 FA1000 Fan Guard 2 3 FD Mount Bracket 2 4 LM Connection Assembly 1 Figure 29 33

37 VFD DISPLAY BOARD ITEM # PART # DESCRIPTION QTY. 1 LM Display Board 1 2 CA Pin Ribbon Cable 18 (457.2mm) Figure 30 GASKETS ITEM # PART # DESCRIPTION QTY. 1 FD Gasket Power Supply Cover 1 2 FD Gasket Connector Mount Panel Figure 31 34

38 SECTION 8 OPTIONS PORTABLE CART The optional cart provides portability for the Super Seal Deluxe system. The four castors with locking provisions and four leveling pads are included. The low profile frame permits positioning the unit under a typical conveyor. The height of the mount is shorter than the floor mount version by approximately 6 inches. With the mount assembly on top of the cart, this keeps the hand crank at a reasonable height. If your conveyor is higher than normal it is possible to special order the longer floor mount adapted to the conveyor or an extension kit. CAUTION: The castor brakes should be checked before and after moving the cart. The leveling pads are to be raised sufficiently to avoid damage when the cart is moved, especially if moving along uneven surfaces. When changing the height of the power supply with the hand crank, always loosen the star shaped locking knob on the side of the mount before turning the crank. The mount should be locked in place by the knob once the desired height has been achieved. Other visible screws on the mount such as the nylon tipped set screws should not be adjusted as they are factory set. When moving the cart it is advised to lower the unit to maintain a low center of gravity. YOKE LOCATION ALLOWS 14" (355mm) FOR COURSE ADJUSTMENT. 59" (1499mm) MAXIMUM HEIGHT 51" (1295mm) MINIMUM HEIGHT SCREW ADJUSTMENT ALLOWS 7 3 4" (197mm) FOR FINE ADJUSTMENT. 24" (610mm) 6" (152mm) 36" (914mm) Figure 32 35

39 MOUNT / CART PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 LM Screw Adjustable Mount Assembly (Less Cart) 1 2 FD Mobile Cart Frame 1 3 CT0031 Caster, 4 (101.6mm) With Brake 4 4 HW0002 Leveling Pad 4 5 NU3132 Stainless Hex Nut ½ x NU0010 Tapped Flat 9 7 MS2466 M8 x 16 MM Long Socket Head Cap Screw 7 8 WA1600 Stainless Lock Washer 5/ PG0001 Poly Hole Plug 2 (50.8mm) Square LM Complete Cart Assembly Figure 33 36

40 STACK LIGHT The Stack Light option may be ordered to provide a visual indication as to the operating status of the power supply. The light is pole mounted on a bracket at the top of the adjustable mount making it visible from a considerable distance. Two lights are provided, green to indicate that the intended output level is maintained and flashing red to indicate a condition that either the output has been lowered to the loss of seal (LSI) set point or that the unit has no output at all. The red flashing interval is controlled by the power supply. The optional stack light works in tandem with the separately provided LSI (continuous signal) output jack and cable furnished as standard equipment for external control purposes. Refer to the basic manual and LSI description for its intended use. R G 2 LSI REMOTE START / INTERLOCKS PROCESS INTERFACE STACK LIGHT 1 CAP INSPECTION CUSTOMER CONN. CAP INSPECTION SENSOR INPUTS Figure 34 37

41 STACK LIGHT PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 LT0151 Light Bulb 24V 2 2 LT0150 Red Lens Gasket (Included with Item 2) 1 4 LT0144 Green Lens Gasket (Included with Item 4) 1 6 LT0145 Light Base and Cover 1 7 LT0215 Mounting Tulip w/mounting Tube 100 mm Tulip Gasket (Included with Item 7) 1 9 FD Spacer Stack Light 1 10 CD0512 Cord Grip 1 11 CA7010 Cable 1 12 CN0153 Connector 1 13 FD Bracket Crank Mount 1 14 MS2466 M8 x 16 Stainless Socket Head Screws 2 15 FD M8 x 1.25P Nut Flat 2 16 MS0106 M5 x 0.8P x 45mm Long - Socket Head Cap Screw - Stainless Steel Figure 35 38

42 MOTION / BACK-UP & FOIL / MOTION GROUPS MOTION/BACK-UP SENSOR ONLY To detect jammed or backed up bottles at a location downstream from the sealing head, a motion sensor may be applied as a back-up detector. This is the most elementary function that is offered for detecting proper bottle flow through the sealing head. Its purpose is to turn off the high frequency output of the power supply before bottles accumulate under the sealing head, damaging the bottle or product because of increased dwell time. This same sensor is a component part of the foil/motion group or more sophisticated deluxe cap inspection system for the Super Seal Deluxe. These are covered later. The Back Up sensor is comprised of three basic components. They are the sensor and reflector assembly, mounting brackets, and junction box for interfacing with the power supply. The sensor assembly has been designed by the manufacturer for high temperature wash downs making it well suited for various processes encountered. Sensor A retro reflective sensor is used which will detect most objects. It is intended to be used primarily in applications where an opaque object will block the effective beam between the sensor and reflector. The sensor has more than enough range, up to two meters, which far exceeds the width of a typical conveyor. The sensor receives 24 VDC from the power supply to operate and in return turns off the high frequency output when a back up of bottle flow is detected. The power supply VFD display and function control keys are used to set the operating parameters resulting from the various conveyor speeds and bottle widths encountered. The sensor has a Light/Dark operate switch that must be left in the Light Mode as received. The sensitivity adjustment will be received factory adjusted and is used to adjust the sensing distance of the sensor. The sensor has three LED indicators to indicate its status. GREEN-ON when there is power to the sensor, but the reflector is not detected, as with a blockage or misalignment. When the reflector is detected the green light goes out. YELLOW-ON when there is power to the sensor and the reflector is detected. It will be out during the time the reflector is not detected, as with a blockage or misalignment. ORANGE-ON when there is power to the sensor and good margin, or viewing ability. It will be out during the time that the reflector is not detected, as with a blockage or misalignment. If the Yellow LED is lit, but the Orange LED is out, alignment should be check and/or the lenses and reflector should be checked and cleaned. If the orange LED is flashing, a short has developed in the wiring. Mounting Brackets Refer to the following picture detail and parts breakdown for the assembly detail. The sensor is to be located on the same side of the conveyor as the power supply to permit cable attachment to the junction box. The location should be a reasonable distance, dependent on conveyor speed, from the exit end of the power supply to prevent bottle back up under the sealing head. Junction Box The Super Seal Deluxe has been designed to conveniently collect all sensor cables at a junction box which in turn connects to the back of the power supply. A junction box with only two connections is required for the more basic Foil/Motion Group as compared to the Deluxe Cap Inspection System. Consequently, when only the motion sensor back up sensor is ordered, it will be necessary to attach a defeat connector to the jack that normally accepts the foil detection cable. This is required to satisfy the logic within the power supply. The defeat connector must remain attached to the foil sensor jack at all times for the back up only detection to properly function. Provisions are made for attaching the Foil/Motion junction box to the yoke assembly near the back panel of the power supply. 39

43 MOTION / BACK-UP SENSOR CONNECTOR PROVISIONS HIGH CAP BACK UP ARRAY TRANSMITTER ARRAY RECEIVER INFEED FOIL SENSOR Mount on the same side of the Conveyor as Cap Sealer. EXIT enercon Mount to Conveyor directly across from each other. LSI REMOTE START / INTERLOCKS PROCESS INTERFACE STACK LIGHT CAP INSPECTION CUSTOMER CONN. CAP INSPECTION SENSOR INPUTS Figure 36 40

44 MOTION / BACK-UP SENSOR PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY. 1 LM Photo reflective Sensor 1 2 FD Sensor Mounting Bracket 1 3 FD Reflector Bracket 1 4 TA0002 Reflector 1-1/4 (31.75mm) Diameter 1 5 FD Sensor Bracket Holder 2 6 WA0002 M5 Lock Washer - Stainless Steel 4 7 NU0021 M5 x.8p Hex Nut - Stainless Steel 8 8 MS2672 M5 x 8P Socket Head Screw - Stainless Steel 8 9 MS0116 M3 x 5P 25mm Long Slotted Pan head - Stainless Steel 2 10 WA0006 M3 - Flat Washer - Stainless Steel 2 11 WA0005 M3 Lock Washer - Stainless Steel 2 12 NU0015 M3 x.5p Hex Nut - Stainless Steel 2 13 LM Foil Defeat Connector 1 14 LM *Sensor Junction Box Not Shown See Figure 33 1 *Order parts from factory factory will assemble ADJUSTMENT CLOCKWISE TO INCREASE NOTE: HARDWARE SAME AS OTHER SIDE Figure 37 41

45 Sensor Set Up Review the Sensor description for the proper switch setting. The sensor should come from the factory with the correct setting and gain adjustment. Ensure the back up sensor is mounted properly and opposite the reflector. The sensor eye and reflector must be in a straight line of sight. Connect the back up sensor to the Back Up jack of the junction box. The defeat connector must be in place for the foil sensor substitution. Connect the junction box output cable to the cap inspection/sensor inputs jack on the power supply. With the power supply energized and no bottles present, all three LED s on the back up sensor should be lit. The power supply will now be used to adjust the timing parameters of the sensor. The following adjustments are to be performed with the unit in a stopped condition. The Out % should be at zero. VFD Display Set Up and Option No message NOTE: Observe Set Up and Options Display on right side of VFD display while performing these adjustments. If a message already exists, press the DONE pushbutton to extinguish any messages prior to starting this procedure. NOTE: If pressing DONE pushbutton does not extinguish the message, the Cap Inspection System has already been selected. Press SETUP SCROLL and the number of times it takes to obtain "FUNCTION CAP INSPECTION. SETUP Press LSI Level." SCROLL pushbutton and observe "Function Press pushbutton and observe "Function Cap Inspection." SELECT Press Inspection Off." Press the Up Arrow Inspection On." pushbutton and observe "Cap and observe "Cap NOTE: Pressing the down arrow will turn the "Cap Inspection Off. Leave it on for the sensors to be activated. DONE Press the pushbutton. The Set Up and Options Screen will display "Function Cap inspection." SCROLL The pushbutton should be pressed repeatedly until the "Function Stall Delay" message appears. Press the SELECT pushbutton and observe "Stall Delay XX Seconds." Press the up/down arrows to select the desired delay time for the back up sensor to activate. This will set the period of time required for bottle accumulation in front of the sensor that will turn off the high frequency output of the power supply. The stall delay setting will be dependent on the conveyor speed and location of the Back Up Sensor. Select a time that is reasonable for the application. Press the DONE pushbutton to return to "Function DONE Stall Delay." Press the pushbutton a second time to return to the main operating screen. The message display will indicate a stopped message and be ready for a start command regardless of being in remote or local control. Remember that if the remote mode is selected, it is necessary to activate the remote mode by pressing the green START pushbutton upon initial power up or when clearing an interlock fault. NOTE: When any of the Cap Inspection functions are selected, the Set Up and Options Display on the VFD screen will be activated. With only the back up sensor ordered, all counts for the displayed cap inspections will continuously read zero (0). If the counts are not at zero (0), see the end of this paragraph for resetting the counts. It should also be observed that the set up portion of the VFD display may read any one of four zero (0) count messages. SELECT These are toggled by using the pushbutton and are "Total Bottles," "Missing Foils," "High Caps," and "Bad Bottles. It is also possible to use 42

46 SCROLL the pushbutton to continuously scroll through these four functions. The scroll mode is turned on and off using the SCROLL pushbutton. It is recommended to not use the scroll mode with the back up sensor. Use the SELECT pushbutton to manually toggle through the Cap Inspection messages and leave the screen with total bottles at zero (0) count. If the counts for any Cap Inspection function are not at zero (0), they can be reset by DONE holding the pushbutton for 2-3 seconds. Sensor Verifications The Super Seal Deluxe has a built-in sensor verification feature that will verify if the sensor is functioning properly. To use this feature when any of the sensors are connected and being used, press and hold the SELECT pushbutton for two to three seconds. The screen will display all of the sensors that may be connected to the Super Seal Deluxe. For the Back Up Detection that this write-up describes, the Beam and Foil letters will be capital letters. The rest of the sensor letters will be in a lower case form. By breaking the beam of the back up sensor with your hand or a bottle, to simulate a stalled condition, the Back Up letters will change to capital letters indicating that the sensor is working properly. Ready for Normal Operation Press the DONE pushbutton to return to normal operation. The Super Seal Deluxe is now ready for operation. The back up sensor may be verified with the unit on or off by blocking the back up sensor eye with your hand or bottle. Motion / Back-Up Sensor Removal In the event that it is desired to remove the back up detection, it can be easily done by disabling the Cap Inspection System. This can be done even with the sensor connected by the following procedure. Press the SETUP pushbutton. Press the SCROLL pushbutton until "Function Cap Inspection is displayed. Press the SELECT pushbutton and observe the "Cap Inspection On" message. Press the arrow and observe that the message indicates "Cap Inspection Off." DONE Press the pushbutton and observe that the message indicates "Function Cap Inspection." Press the DONE pushbutton one more time to extinguish the set up screen. The Super Seal Deluxe is ready to operate in its basic mode of operation with or without the sensor attached. FOIL / MOTION GROUP This option includes the previously described Back- Up Detector with the addition of a missing Foil Detector. The Back-Up Detector serves to detect the accumulation of bottles that may back up under the sealing head. Its purpose is to turn off the high frequency output of the power supply before bottles accumulate under the sealing head, damaging the bottle or product because of increased dwell time. Refer to the previous Back-Up Option description for assembly illustrations and operation. The Foil Detector portion uses two sensors that have their outputs integrated to determine if a foil liner is missing from a bottle. When a bottle with a missing liner passes by the two sensors, a momentary electrical pulse is developed. This pulse is sent to the Super Seal Deluxe as a missing foil indication. Internal circuitry and programming commands permit delaying and controlling the pulse width received, then produce a "Missing Foil" signal through a relay contact closure to an external bottle eject or gating mechanism. An advantage of the Super Seal Deluxe is that it can be used on containers that have handles or are box shaped without the use of a third sensor. Internal circuitry compensates for these irregular shapes. Sensors Two sensors are used for the missing foil detection circuit. An inductive proximity sensor is used to detect the aluminum liner in the bottle. The second sensor is a diffused reflective photoelectric sensor that will detect each bottle passing. This style of beam sensor does not require a reflector. Both of these sensors receive 24 VDC power from the power supply and, in turn, function to send a signal to the power supply via the junction box for processing. Both sensors have adjustment provisions and red LED indicators to provide an indication of their operating status. Adjustments will be described later. 43

47 Mounting Brackets Brackets are furnished to mount the missing foil detector sensors at the exit end of the sealing head. Provisions are made to attach the bracket to the yoke of the power supply shown in the following illustration. This permits the sensors to travel with the power supply and sealing head as they are raised and lowered. Slots are provided in the various brackets to permit locating the sensors in their best position. Bottle Counts Bottle counts are established for high caps (not used with Foil/Motion Group), missing foils, and bad bottles and total bottles. Each counter has the capacity to obtain a count of 999,999. If dependent on the counters, they should be reset prior to reaching their maximum count, with the Missing Foil Sensor, the Missing Foil and Bad Bottles should read the same. Total bottle count is an indication of all bottles that have passed through the sealer. All bottle counts should be at zero or a record kept of the counts prior to starting a production run. The following Setup Procedure will include steps for setting the counts to zero. NOTE: Continued after following illustrations. FOIL / MOTION GROUP CONNECTOR PROVISIONS HIGH CAP BACK UP BOTTLE BACK-UP SENSOR ARRAY TRANSMITTER ARRAY RECEIVER INFEED FOIL SENSOR EXIT enercon FOIL LINER DETECTOR 20 ft. (6.1m) OF CABLE BLACK (NO) RED (NC) WHITE (COM) FOR CUSTOMER BOTTLE EJECT USE (AS REQUIRED) GREEN (NO) FOR CUSTOMER MISSING FOIL USE ORANGE (COM) (AS REQUIRED) BLUE (NO) FOR CUSTOMER HIGH CAP YELLOW (COM) USE (AS REQUIRED) BROWN (NO) FOR CUSTOMER STALLED BOTTLE VIOLET (COM) USE (AS REQUIRED) enercon SUPER SEAL - DX LSI REMOTE START / INTERLOCKS PROCESS INTERFACE STACK LIGHT CAP INSPECTION CUSTOMER CONN. CAP INSPECTION SENSOR INPUTS Figure 38 44

48 FOIL / MOTION GROUP PARTS BREAKDOWN ITEM # PART # DESCRIPTION QTY 1 FD Cross Bracket 1 2 FD Angle for Sensor Mounting 1 3 FD Mounting Bracket - Foil Sensor 1 4 FD Mounting Bracket - Beam Sensor 1 5 LM Foil Sensor Assembly 1 6 LM Sensor Junction Box 1 7 LM Cable Assembly Cap Inspection Output 1 8 NU0018 M5 Acorn Nut - Stainless Steel 4 9 MS0108 M5 x 8P, 25mm Long Screw - Stainless Steel 4 10 MS2673 M5 x 8P, 12mm Long Socket Head Screw - Stainless Steel 4 11 WA0002 M5 Lock Washer, Stainless Steel 8 12 WA0003 M5 Flat Washer 8 13 MS2466 M8 x 16 Socket Head Screw - Stainless Steel 2 14 WA1630 M8 Lock Washer - Stainless Steel 4 15 WA4090 M8 Washer - Stainless Steel 2 16 MS0033 M4 x.7p, 30mm Long Pan Head Screw - Stainless Steel 2 17 WA0004 M4 Lock Washer - Stainless Steel 2 18 MS0014 M8 x 1.25P, 20mm Long Hex Head Screw - Stainless Steel 2 19 LM Photo reflective Sensor 1 REFERENCE MOTION/BACK-UP SENSOR PARTS BREAKDOWN. Figure 39 45

49 CAP INSPECTION SYSTEM CAP INSPECTION SYSTEM FUNCTIONS The Enercon Cap Inspection System enhances the bottle detection capabilities for a packaging line. Several features are added to the basic Missing Foil and Bottle Back Up detection options previously defined. The additional features include High Cap sensing, Stalled Bottle Arrays for sensing improper dwell time under the sealing head and provisions for Automatic Start by detection of bottles feeding into the sealer. High Cap Sensing provides a programmed signal, timed to eject the bottle, whereas Stalled Bottle and Infeed Start use bottle sensing to stop and start the power supply accordingly. Cap Inspection Features Back Up Detection Missing Foil Detector Stalled Bottle Detector High Cap Detection Automatic Start Bad Bottle Count: High Cap, Missing Foil Total Bottle Count Missing Foil/High Cap Eject Signal - Adjustable Eject Pulse Width - Adjustable Eject Pulse Delay Sensor Verification Feature Function Control Keys for Programming Set Up Digital Display Readout Low Voltage Sensors, 24 VDC Cable with relay set for Eject, Missing Foil, and High Cap. Isolated contacts for external use. Back Up Detection The Back-Up Detector serves to detect the accumulation of bottles that may back up under the sealing head. Its purpose is to turn off the high frequency of the power supply before bottles accumulate under the sealing head damaging the bottle or product because of increased dwell time. Missing Foil Detection The foil Detector portion uses two sensors that have their outputs integrated to determine if a foil liner is missing from a bottle. When a bottle with a missing liner passes by the two sensors, a momentary electrical pulse is developed. This pulse is sent to the Super Seal Deluxe as a missing foil indication. Internal circuitry and programming commands permit delaying and controlling the pulse width received, then produce a "MISSING FOIL" signal through means of a relay contact 46 closure to an external bottle eject or gating mechanism. An advantage of the Super Seal Deluxe is that it can be used on containers that have handles or are box shaped without the use of a third sensor. Internal circuitry compensates for these irregular shapes. Stalled Bottle Detection This Stalled Bottle Detector provides protection for bottles that remain under the sealing head for longer than normal periods of time. Protection is intended for conditions of conveyor shutdown or jams that leave bottles stationary under the sealing head while the power supply is energized. When utilized, the Stalled Bottle Detector will also function for bottles retained under the sealing head when the power supply is not energized, but this is of no consequence to the bottle. A series of infrared transmitters and receivers establish an array of detection under the sealing head. The detected "STALL" signal will be delivered to the power supply to turn its high frequency output off. The Back Up sensor and Stalled Bottle Detection circuits share the same timing circuits and message information on the VFD display. Both circuits are engaged in turning the high frequency output of the power supply off in the event that an accumulation of bottles has occurred. Therefore, the same time settings are used. The Back Up sensor detects conditions prior to bottles backing up into the coil from jams or conveyor stoppage, whereas the arrays detect conditions for accumulation directly under the sealing head. The transmitting array is divided into three zones. Each zone has a separate LED to indicate that power is applied and that the light transmitters are functioning. If one of the three LEDs is out, it will be an indication of failure and the array should be replaced. The receiving array uses two LEDs to indicate proper performance. The LED closest to the end cap is used to indicate power is applied and will remain lit with the system energized. The other LED located inward on the array is lit when all of the light receivers are accepting light from the transmitter. The arrays should be functioning properly when received from the factory. However, some applications or bottle sizes may require adjustment.

50 Blocking the arrays by hand or with a bottle should cause the inward receiver LED to extinguish. One should then pass a bottle of the size to be used at normal conveyor speed through the arrays. The power supply and sealing head should be at the normal sealing height which controls the position of the arrays. The arrays are functioning properly when the bottle passes completely through the arrays with the inner LED remaining off. This applies to when the bottle passes between the lens of the arrays. If a gain adjustment is required, the potentiometer is accessible by removing the screw in the end cap of the receiver array that contains a cord. A miniature screwdriver like used on eye glasses should be used to adjust the gain. Proper adjustment exists when the inner LED is normally lit, extinguishing as a bottle passes between the arrays. No intermittent flashing of the LED should occur. The delay for power supply output shutdown is determined by the programmed time delay settings as previously described. The adjustment procedure is described later. The exit sensor functions in the same manner as the back up but is used to reset the control timer as bottles pass through the arrays. High Cap Detection High Cap Detection employs a photoelectric sensor with a fiber optic output. The fiber optic output establishes a visible red beam between transmitter and receiver of the sensor. This creates a narrow beam of light passing between transmitter and receiver to be positioned over the bottles passing under it. Since high Cap and Missing Foil detection are conditions for bottle reject, these functions are detected at the same position on the conveyor. The high Cap feature necessitates placing the sensors prior to the bottle entering the sealing head. Thus, the assembly holding the sensors is located prior to the bottle approaching the sealing head. The High Cap and Missing Foil Detection circuits share the same timing circuits and message information on the VFD display. Both of these functions are engaged in providing an eject command to an external eject device. Either circuit will produce the eject signal. It is conceivable that both conditions could exist for one bottle producing one eject command. Adjustments will be defined later. Automatic Start The same style sensor used for back up and exit detection is applied on the bottle infeed side for automatic starting. When intermittent bottle flow exists, this infeed sensor serves to start and stop the power supply as required. When utilized, each bottle passing will deliver a signal to the power supply indicating a bottle is entering the sealing head. The power supply is immediately started with the first signal received which can occur for a single or continuous string of bottles. The power supply timer will be reset for each bottle detected. The timer interval has been fixed at 30 seconds which will accommodate various conveyor speeds. Once AUTO START has been selected by the function control keys, no other adjustments are required. This Automatic Start Feature is only intended to be used with the Cap Inspection system. One should not use the Remote Start feature with the Automatic Start as both conditions would have to be satisfied for the unit to start. Sensor Information The Automatic Start, Exit, and Back Up sensors are comprised of the retro-reflective sensor, reflector, and mounting brackets for each as illustrated in Figure 40. The sensor selected has been designed by the manufacturer for high temperature wash downs making it well suited for the various applications encountered. All Cap Inspection sensors receive 24 VDC from the power supply to operate when connected to jacks of the Cap Inspection Junction Box. Detected signals are returned to the power supply via the same cables and junction box. The sensors have a detection range of up to two meters which far exceeds the width of a typical conveyor. A LIGHT/DARK operate switch is to be left in the LIGHT mode as received. The sensitivity adjustment is received from the factory adjusted. The potentiometer uses a clockwise direction to increase the sensing range. Three LED lamps are used to indicate the sensor status. GREEN-ON when there is power to the sensor, but the reflector is not detected, as with a blockage or misalignment. When the reflector is detected the green light goes out. YELLOW-ON when there is power to the sensor and the reflector is detected. It will be out during the time the reflector is not detected, as with a blockage or misalignment. 47

51 ORANGE-ON when there is power to the sensor and good margin, or viewing ability. It will be out during the time that the reflector is not detected, as with a blockage or misalignment. If the Yellow LED is lit, but the Orange LED is out, alignment should be check and/or the lenses and reflector should be checked and cleaned. If the orange LED is flashing, a short has developed in the wiring. Refer to Figure 40 for the assembly and cable installation details. The Automatic Start, Exit, and Back Up sensors are to be located on the same side of the conveyor as the power supply to permit cable attachment to the junction box. The automatic start sensor location should be positioned some distance from the power supply but will be limited by the cord length. Starting will be instantaneous and the 30 second turn off delay is more than enough for varying conveyor applications. Bottle Counts Bottle Counts are established for High Caps, Missing Foils, Bad Bottles, and Total Bottles. Each counter has the capacity to obtain a count of 999,999. If dependent on the counters, they should be reset prior to reaching their maximum count. When using the Cap Inspection System, the Bad Bottle Count should equal the sum of High Caps and Missing Foils. Total Bottle count is an indication of all bottles that have passed through the sealer. All bottle counts should be at zero or a record kept of the counts prior to starting a production run. The following set up procedure will include steps for setting the counts to zero. Junction Box All sensor cables are connected to the Junction Box as illustrated, which, in turn, is connected to the power supply. Set Up Assemble and mount the Cap Inspection System as illustrated. The various cables and Junction Box are to be connected as shown. Energizing the power supply will provide power to the sensors. The power supply will not have to be started for the sensors to operate and function as intended. The nine wire cap inspection output cable is provided for delivering the detected Missing Foil and High Cap signals to external circuits. Isolated relay contacts, normally open are provided for each as well as a third set, normally open and normally 48 closed for bottle eject. The eject signal will be a result of either Missing Foil or High Cap since both require the eject response and are detected at the same place on the conveyor line. These signals will be momentary in nature so they can be used as "triggers" for external control purposes such as counters, lights, and an eject mechanism. It is left for the user to determine how these signals will be used and processed. The proximity sensor for foil detection is to be positioned using the brackets and adjustments so that it is centered over the bottle passing under it. Note that the housing is not symmetrical. A recessed dimple in its face represents the center. The proximity switch should be located as close to the cap as possible. This is particularly important with closures that are small and have recessed liners like sports bottles. The fiber optic beam should be located and positioned as close to the closure as possible. This will partly be dependent on factors of container variation or bottle bounce on the line to avoid false sensing. The proximity and beam sensors both incorporate potentiometer adjustments for their gain or range of adjustment. These should arrive from the factory pre-adjusted but if not, are usually applied with their potentiometers adjusted in a clockwise direction toward maximum range. It is only the beam sensor that may require some attenuation if the range is too long causing it to detect objects beyond the width of the conveyor. Both sensors will have red LEDs light up when sensing their object. Properly adjusted and functioning, it is only when a bottle with a missing liner passes by that the missing foil circuit will be activated. The High Cap sensor with fiber optic cables will come with the cables attached to the sensor. These have been cut and inserted into the sensor. Care should be taken to avoid bending or harming the fiber optic cable. The switch of the sensor inside the cover next to the cord is to be in the light operate position. The cover has markings of D and L to distinguish which position is for dark or light operation. The gain potentiometer is adjusted clockwise. It is the orange LED within the cover that will indicate the sensor has good margin. If it is out, one should check the alignment by ensuring the fiber optic cables are securely mounted in the brackets and sensor and that they have not been bent or damaged.

52 With all the sensors in place, energize the power supply but do not start it. This will supply power to and energize the sensors. The following adjustments are to be performed. The Out % on the VFD display should be at zero. VFD Display Observe the Set Up and Options Display on the right side of the VFD Display while performing these adjustments. If a message already exists, press the DONE pushbutton to extinguish any messages prior to starting this procedure. DONE If pressing does not extinguish the message, the Cap Inspection System has already SETUP been selected. Then press and the number of times it takes to obtain "FUNCTION CAP INSPECTION." SCROLL When the right side of the VFD Display has no messages shown, press the SETUP pushbutton and observe "FUNCTION LSI LEVEL." SCROLL Press the pushbutton and observe "FUNCTION CAP INSPECTION." Press the SELECT pushbutton and observe "CAP INSPECTION OFF." Press the arrow and observe "CAP INSPECTION ON." NOTE: Pressing the arrow will turn the Cap inspection System off. Leave it on for the Cap Inspection System to be activated. Press the DONE pushbutton. The Set Up and Options screen should now display "FUNCTION CAP INSPECTION." The Scroll Function Key is now used to move through the various adjustments to be set for the Cap Inspection System. SCROLL The pushbutton should be pressed repeatedly until the "FUNCTION STALL DELAY" message appears. SELECT Press the pushbutton and observe "STALL DELAY XX SECONDS." 49 Use the arrows to select the desired delay time for the BACK UP SENSOR and ARRAYS to activate. This setting will be common for the Back Up and Stalled Bottle Arrays. This will set the period of time required before bottle accumulation will turn off the high frequency output of the power supply. The stall delay setting will be dependent on the conveyor speed and location of the Back-Up Sensor. The stall delay for the arrays will be influenced by the output % level applied. Higher outputs will require a shorter stall delay. Select a time that is reasonable for the application. Press the DONE pushbutton to return to the "FUNCTION STALL DELAY" message. Now press SCROLL the pushbutton as many times as necessary to go to the message "FUNCTION EJECT TIME. Press the SELECT pushbutton and observe "EJECT TIME XX SECONDS." This will be the period of time that the signal for eject will be present. Use the arrows to adjust the time. A range of.01 to 2.55 seconds is available. This setting must be determined by the user and is dependent on how this signal will be applied. Press DONE the pushbutton to return to the "FUNCTION EJECT TIME" message. Press the SCROLL pushbutton and move to the "FUNCTION EJECT DELAY" message. Press the SELECT pushbutton and observe that the "EJECT DELAY XX SECONDS" message is present. This time will allow adjusting the time between when the eject signal is detected to when it is actually delivered to external control for processing. The time is variable from.1 seconds to 25.5 seconds. Therefore, the eject command can be immediate or have considerable delay before ejecting the bottle. Use the arrows to set the "EJECT DELAY." NOTE: This EJECT DELAY procedure applies to the "MISSING FOIL" and "HIGH CAP" detected signal. Both missing foil and high cap sensors detect their faults at the same position on the line making the eject time coincident. Once the "EJECT DELAY" has been determined and set, press the DONE pushbutton to return to the "FUNCTION EJECT DELAY" message. If it is

53 intended to use the AUTO START FUNCTION, press the SCROLL pushbutton the number of times required to observe "FUNCTION AUTO START." Press the SELECT pushbutton to observe if AUTO START is ON or OFF. Use the arrows to turn the AUTO START ON. The Infeed Sensor will now be used to start the unit. Bottle interruption of thirty seconds will cause the power supply to stop until another bottle comes along. Press the DONE pushbutton to return to DONE "FUNCTION AUTO START." Press the pushbutton a second time to return to the main operating screen. The unit is now ready for normal operation using the Cap Inspection System. NOTE: One should determine if the bottle counts should be set to zero before performing the following procedure. With the Cap Inspection System activated, the Set Up and Options screen can be scrolled through manually with the SELECT pushbutton. If any DONE counts are not at zero, holding the pushbutton for 2-3 seconds will reset the count to SELECT zero. The pushbutton manually scrolls through the four messages: TOTAL BOTTLES, MISSING FOILS, HIGH CAPS, and BAD BOTTLES. Pressing the SCROLL pushbutton will cause the display to scroll between the four SCROLL functions. Pressing the pushbutton a second time will cause the scroll to stop and freeze on whatever function was displayed at the time the scroll key was pressed. While in a scroll mode of DONE operation, pressing the pushbutton for 2-3 seconds will also cause count resets. It is recommended that resets be done while manually scrolling the four counts. Sensor Verification The Super Seal Deluxe has a built-in sensor verification feature that will verify if any connected sensor is functioning properly. To use this feature, press and hold the SELECT pushbutton for 2-3 seconds. The screen will display the sensors by showing them in a lower case form. Activating any of the sensors through simulation will change the 50 letters to upper case form indicating that the sensor signal has been received properly. This test can be performed while the power supply is on or off. Ready for Normal Operation Press the DONE pushbutton to return to normal operation. The Super Seal Deluxe is now ready for operation. Any of the sensors being used may be verified by passing a "bad" bottle with missing foil or high cap through the sensors. Stalling a bottle in front of the Back Up sensors or arrays will cause a "STALLED BOTTLE DELAY" following the period of delay selected. The Automatic Start feature may be verified if it has been selected. Remember that it will be normal for the inner LED for the receiver array to be extinguished with normal bottle flow through the arrays. Cap Inspection System Removal In the event it is desired to remove the Cap Inspection feature, it can easily be done by disabling the Cap inspection System. This can be done even with the sensors connected using the following procedures. Press the SETUP pushbutton. Press the SCROLL pushbutton until "FUNCTION CAP INSPECTION" is displayed. Press the SELECT pushbutton and observe the "CAP INSPECTION ON" message. Press the arrow and observe that the message indicates "FUNCTION CAP INSPECTION OFF." DONE Press the pushbutton and observe that the message indicates "FUNCTION CAP INSPECTION." Press the DONE pushbutton one more time to extinguish the set up screen. The Super Seal Deluxe is now ready to operate in its basic mode of operation with or without sensors attached.

54 CAP INSPECTION OPTION INSTALLATION DIAGRAM Junction Box Sensor Connections Cap Inspection Inputs Main Panel LSI REMOTE START / INTERLOCKS PROCESS INTERFACE STACK LIGHT CAP INSPECTION CUSTOMER CONN. CAP INSPECTION SENSOR INPUTS 1 Infeed Sensor (Auto Start) FOR CUSTOMER BOTTLE EJECT USE (AS REQUIRED) FOR CUSTOMER MISSING FOIL USE (AS REQUIRED) FOR CUSTOMER HIGH CAP USE (AS REQUIRED) FOR CUSTOMER STALLED BOTTLE USE (AS REQUIRED) BLACK (NO) RED (NC) WHITE (COM) GREEN (NO) ORANGE (COM) BLUE (NO) YELLOW (COM) BROWN (NO) VIOLET (COM) Connection Cable 20ft of Cable 6 Exit Sensor enercon SUPER SEAL - DX 7 Back-Up Sensor 2 High Cap Sensor 5 Receiver Array 3 Missing Foil Detector 4 Transmitter Array Figure 40 51