Super Seal™ Cap Sealer Induction Cap Sealing Machine. Enercon's Super Seal™ induction cap sealers are the industry standard for cap sealing. These induction cap sealing machines have sealed more containers at more packaging operations that than any other brand in the world.
To watch a brief video on induction sealing basics please click on the play button above. To see the rest of the Handbook's tips and techniques please scroll the document or use the bookmarks provided.
Why Enercon? Variety Enercon Has The Largest Range Of Air-Cooled Induction Cap Sealing Systems Available In The Industry Today, With 8 Models And Multiple Configurations To Suit Your Specific Needs.
Air-cooled Systems Table Top
Conveyor Mount
Specialty / Capless
Auto Jr.
Super Seal™ (SS50 – SS100)
Pneumatic Jr.
Super Seal™ Jr.
Super Seal™ Deluxe
Rotary / Indexing
Super Seal™ Max
Pressure Belt
Tunnel Sealing Head Design Enercon’s unique tunnel sealing head design (offered as standard for 53mm closures and smaller) increases electromagnetic power coupling into the foil, resulting in greater sealing efficiency. This greater efficiency permits faster line speeds at an equal power level.
Outstanding Service Enercon stands behind our equipment and customers with 24-hour technical assistance, rapid parts shipment, as well as loaner and exchange programs. Our worldwide network of representatives provides local expertise both before and after the sale. For immediate assistance online go to: www.enerconind.com/support..
Selecting the Right Induction Sealing System Questions to Answer With Cap
Capless
1. 2. 3. 4. 5. 6.
Type of Product? Temperature of Product? Size of Container? Container Material? Diameter of Cap? Style of Cap: Child-Resistant, Dispensing, Snap Cap, Standard Flat, Push/Pull, Flip-Top? 7. Liner Material? 8. Conveyor Speed (Feet or Meters per Minute)? 9. Is Wash Down Required?
1. 2. 3. 4. 5. 6. 7. 8.
Type of Product? Temperature of Product? Diameter of Container Opening? Size of Container? Container Material? Liner Material? Inline, Rotary or Indexing Production Line? Line Speed (Bottles per Minute – Rotary & Indexing, Feet or Meters per Minute – Pressure Belt)?
Induction Sealing Rules Of Thumb Glass containers with dry product can always be sealed. Check with your inner seal supplier when sealing liquids in glass. The induction sealing process is still effective when liquid product is on the container lip, with the exception of some liquids on glass containers. The operating frequency of the power supply determines the heating pattern of the electromagnetic field. Higher frequency results in heat concentration on the outside edge of the inner seal, which is beneficial for the one-piece type liners. As the frequency is lowered, the heating tends to be more uniform across the inner seal. This is desirable for a wax-bonded type 2-piece inner seal. Electromagnetic radiation of the type and power level used is not harmful to humans.
1 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Service Options Startup Made Easy Enercon offers a discounted Startup service for our customers who are unfamiliar with the installation and use of induction cap sealing equipment. As part of the service, an experienced Enercon Field Service Engineer will review your cap sealer installation, making sure that everything has been done correctly. Or, if you prefer, the Field Service Engineer can supervise your installation of the cap sealing system. Once your cap sealing system is up and running, the Field Service Engineer will provide hands-on training for your operators, as well as training on routine preventive maintenance and troubleshooting for your maintenance personnel.
Preventive Maintenance Routine Preventive Maintenance is at the heart of every successful manufacturing operation. Our experience over the past 30 years has shown that an aggressive preventive maintenance program is the best insurance against downtime. Solid periodic maintenance will also prolong the life of your equipment. We have in place a preventive maintenance program, our PMV service, which is designed to give you that insurance. At a discounted rate we will supply a Field Service Engineer who will review all of your Enercon equipment. In addition to ensuring that your Enercon induction cap sealing systems are tuned up and performing correctly, our Field Service Engineer will provide hands-on training for your operators and maintenance personnel. He will also identify critical spare parts which should be a part of your maintenance inventory and help you refine your ongoing maintenance program. To learn more about our Startup and Preventive Maintenance visits, contact Paul Reed at (262) 2556070, or e-mail him at [email protected] He is ready to tell you more about these valuable programs and provide you with a comprehensive pricing package.
Field Service In conjunction with our Startup and PMV service, Enercon also provides emergency field service that gets consistently high ratings from our customers in the packaging industry. When a problem cannot be resolved by your maintenance department we will provide a Field Service Engineer to come to your plant and repair your equipment. With extensive hands-on experience and direct access to our Engineering Department, our Field Service Engineer will ensure that the problem you are experiencing is resolved. He will also determine if anything else in the system may require repair. For more information on Field Service visits contact Paul Reed at (262) 255-6070, or e-mail him at [email protected]
International Service Check with your local representative for the availability of International Field Service.
3 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Laboratory Policies And Procedures In-House Testing Enercon’s Induction Cap Sealing Laboratory can help you determine the proper sealing head and power rating, as well as test the suitability of your cap, bottle and liner material for your particular application. The lab has available every model, power rating and sealing head that Enercon manufactures, in order to duplicate actual production line conditions accurately. Equipment research and development, and applications testing, are continuously conducted in the laboratory. This is an important element in Enercon’s commitment to supply you with technological leadership in the constantly changing packaging industry.
Induction Cap Sealing Trials Enercon’s Induction Cap Sealing Laboratory is equipped with a conveyor and tachometer to reproduce your line speed requirements accurately. The laboratory is also equipped with all of the current production models of cap sealing equipment, as well as all of the standard and specialty sealing heads produced by Enercon. Tests can be performed on all sizes of containers and caps, from a small tube to a 2-gallon jug, with caps from 5mm to 120mm and larger. As a result of our cooperation with the leading liner material manufacturers, the laboratory also has a supply of practically all liner materials that are available. Therefore, we can work with the liner material you have already selected or refer you to the liner material manufacturers who can help you select the material that is best for your application. The laboratory is also equipped with a Pack-Vac Leak Detector and a torque meter. The Leak Detector can accommodate all but the largest containers, for testing the hermetic seal strength, and the torque meter allows the testing of the application and removal torque. COST:
There is no charge for the test itself. We do request that you contact our Sales Department for an RCN (Return Control Number) and send your samples to our facility freight prepaid. Let us know if you would like your samples returned to you.
RESULTS:
You are welcome to visit our facility and observe the running of your sample. We will arrange to have your samples available at the time you wish to visit. Typically the visit would last three to five hours, usually from 9 a.m. until 2 p.m., with a break for lunch. You will be given a demonstration of the procedures followed for your sample. After a thorough discussion of your application, you are welcome to take a tour of the facilities and meet with members of our engineering staff to answer any technical questions you may have.
DATA SHEET:
If you are unable to visit, the results of your sample will be forwarded to you. Any questions you may have are welcomed by our Sales Engineers.
TIME:
Your sample will be tested in a timely manner, generally within one to two weeks.
4 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Seal Problem Troubleshooting Tips Symptom
Partial seal, weak seal, no seal.
Probable Cause
Possible Solution
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 treated with flame, corona, or chemically. f. Imperfections in container finish, land area.
a. See Page 11 for Operating Window Setup Procedure. b. See Page 10 for Sealing Head Alignment. c. See Page 8 for Suggested Application Torque. d. Contact your supplier, or send samples for testing. e. Contact your supplier.
g. Product is touching liner, heat sink effect. Seal extremely difficult to remove (1piece liner).
Cap extremely difficult to remove (2piece liner).
a. Power from sealer set too high.
a. See Page 11 for Operating Window Setup Procedure. b. Ensure line speed is correct. See Page 11 for Operating Window Setup Procedure.
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.
e. Product touching liner, heat sink effect.
Burnt Cardboard Liner.
Low or no removal torque.
Pinholing.
Pinwheel effect on liner.
f. See Page 7 to help identify problem, contact container manufacturer. g. Check the fill level of product.
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. See Page 11 for Operating Window Setup Procedure. b. See Page 10 for Sealing Head Alignment. c. See Page 8 for suggested application torque. d. See Page 11 for Operating Window Setup Procedure. Material in cap and backing material on liner may be too compatible – contact your supplier. e. Check the fill level of product. a. See Page 11 for Operating Window Setup Procedure. b. See Page 10 for Sealing Head Alignment, check for cocked cap. Do not stop conveyor while unit is still running. c. See Page 8 for suggested application torque or contact your supplier. d. Contact your supplier.
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. See Page 8 for suggested application torque.
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. See Page 11 for Operating Window Setup Procedure. b. Contact your supplier or send samples for testing.
a. Retorquing too soon after induction sealer.
a. Move Retorquing equipment further downstream from sealer. b. See Page 11 for Operating Window Setup Procedure.
b. Wax was not completely.
absorbed
into
pulpboard
b. See Page 8 for suggested application torque. c. Contact your Sales Manager to discuss possible solutions.
5 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Liner Types Before Cap Is Applied To Container And Induction Sealed
Multilayer Liners Multilayer liners consist of 4 basic components, as shown.
C
B
A Pulpboard
Foil
Wax
D Polymer
B
A
Wax
Pulpboard After Cap Is Applied To Container And Induction Sealed
C Foil
When a multilayer liner passes through the induction field of the sealing head the following occurs:
D
1. The foil is heated to a temperature that will allow the polymer to melt and flow. 2. The polymer flows around the land area of the container filling any voids. 3. The wax is melted and absorbed into the pulpboard, or similar absorbent material. 4. The polymer cools and hardens creating the hermetic seal.
Polymer
Before Cap Is Applied To Container And Induction Sealed
Single-Piece Liners Single piece liners consist of 2 basic components, as shown.
A
B Polymer
Foil
When a single-piece liner passes through the induction field of the sealing head the following occurs:
After Cap Is Applied To Container And Induction Sealed
A Foil
1. The foil is heated to a temperature that will allow the polymer to melt and flow. 2. The polymer flows around the land area of the container filling any voids. 3. The polymer cools and hardens creating the hermetic seal.
B Polymer
6 Enercon Industries Corporation
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email: [email protected]
Cap / Container Issues Good Container Lip/Liner Contact Good contact between the liner material and the container lip is very important. This goes hand in hand with the amount of torque applied, but can be a problem even when the torque levels are good. The land area of the container should be wide enough and rigid enough to support the pressures and heating required for a good seal.
Poor Container Lip/Liner Contact A thin or weak land area can cause poor contact between the liner material and the container lip. When the land area is too thin there may not be enough rigidity in the land area to support the pressures and heat required for a good seal.
Container Lip Deformations Gaps between the land area and liner material can be the result of any number of problems, from mold imperfections to container material issues. Regardless of the cause, any gap between the liner and container land area may cause overheating and failure of the seal. A gap caused by fall away of the land area, as well as a gap caused by a protrusion, is shown. These defects can typically be detected on the container land area before the container is capped.
Cocked Cap A cocked cap is usually due to a problem with the capping process or a cap or container problem. The gap created can cause overheating and the cap itself may actually jam the container under the sealing head causing the liner to overheat severely.
7 Enercon Industries Corporation
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email: [email protected]
Torque Requirements One of the most common causes of poor or inconsistent sealing is an improperly torqued cap. Whether the torque is too low or too high, the end result is usually an air gap between the lip of the container and the liner material. This air gap will usually cause overheating of the liner, but at the very least will create a gap too large for the polymer to fill. The following table is provided as a general rule of thumb for determining the torque required for your cap size. For exact torque requirements, contact your cap manufacturer.
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 (.79-1.13nm) 8-12 in./lbs (.9-1.35nm) 9-14 in./lbs (1-1.58nm) 10-16 in./lbs (1.13-1.8nm) 12-18 in./lbs (1.35-2.03nm) 15-25 in./lbs (1.69-2.82nm) 17-26 in./lbs (1.92-2.93nm) 18-27 in./lbs (2.03-3.05nm) 19-30 in./lbs (2.14-3.38nm)
53mm 58mm 63mm 70mm 83mm 89mm 100mm 110mm 120mm
21-36 in./lbs (2.37-4.06nm) 23-40 in./lbs (2.59-4.51nm) 25-43 in./lbs (2.82-4.85nm) 28-50 in./lbs (3.16-5.65nm) 40-60 in./lbs (4.51-6.78nm) 45-65 in./lbs (5.08-7.34nm) 50-70 in./lbs (5.65-7.90nm) 52-73 in./lbs (5.87-8.25nm) 55 -75 in./lbs (6.21-8.47nm)
8 Enercon Industries Corporation
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Liner Issues
Good Seal A good seal will have good adhesion for the entire circumference of the bottle opening. Wrinkling will be at a minimum and on multilayer liners the cap will have no darkening that would indicate overheating. No o discoloration n indicatess properr outputt level..
Poor Seal When the output is too low, line speeds too high, or the sealing head misaligned the liner material will not adhere properly to the lip of the bottle. This can range from a seal that lets go under light pressure to no adhesion to the lip of the bottle. On multilayer liners there may also be swirling of the liner due to poor wax absorption into the backing material.
Overheated Seal When the output is too high, or line speeds too slow, overheating of the liner will occur. The liner will often wrinkle badly, melt into the lip of the bottle, and give off a burned smell. The burned smell can also contaminate your product. On multilayer liners the pulpboard will show signs of discoloration or burning, depending on the severity of the overheating.
Darkening g orr burning g indicatess outputt levell needss to o be e lowered.
Easy-Peel Liners Easy-peel liners seal tightly to the lip of the bottle, but allow for a clean peel from the bottle.
Tamper-Evident Liners Tamper-evident liners seal tightly to the lip of the bottle, but leave part of the liner on the lip when opened. This is used to show evidence that the bottle has indeed been opened.
9 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Sealing Head Alignment Tunnel Sealing Head
Flat Sealing Head
Deep Tunnel Sealing Head The Liner Must Be Aligned As Shown
1 8'
To 14' Gap (3 To 6mm)
SIDE VIEW
FRONT VIEW READY RUN REMOTE AUTO AUTO
REMOTE
TUNNEL SEALING HEAD
SETUP
SELECT
SCROLL
DONE
START
STOP
Super Seal ™ Deluxe
FLAT SEALING HEAD
'D'
1 8' GAP RECOMMENDED
'D'
'D'
CONVEYOR
'D'
CONVEYOR
NOTE: 'D' (Distance) Must Be Equal Side To Side And Back To Front Above Conveyor For Optimum Performance Of Sealing Head.
Sealing Head Alignment Quick Setup Step 1:
Level and center Sealing Head over conveyor or product.
Step 2:
Fill 2 containers with product to duplicate production weight.
Step 3:
Place one container at each end of the Sealing Head.
Step 4:
Place a proper thickness gauge on top of each cap.
Step 5:
Lower the Sealing Head onto the gauge. The fit should be snug with no change to gap when the gauge is removed.
Step 6:
Align guide rails to ensure the containers enter and exit the Sealing Head properly centered.
Note: The “1” Sealing Head should be initially set up like the Flat Sealing Head and then skewed to the proper position for the cap size being sealed. Ensure there are no metal guide rails located beneath the sealing head.
Setup Information We recommend that a record be kept of the setup information for each product run with your Cap Sealer. This information helps ensure consistent and accurate change over between products. This information also helps troubleshooting of sealing issues if they arise. The Miscellaneous Section in your manual contains a table for recording this information.
10 Enercon Industries Corporation
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web: www.enerconind.com
email: [email protected]
Operating Window Setup Procedure As with any piece of equipment it is important to know your Cap Sealer’s operating parameters. The following is a step-by-step explanation of how to determine the Operating Window for each package run on a given piece of equipment. 1.
Ensure the unit is installed properly (refer to your Operations Manual) and the sealing head is at the correct height, centered, and is parallel over the conveyor (refer to Page 10).
2.
Ensure the conveyor speed is set properly for the package being tested.
3.
Ensure the container and caps are free of defects (refer to page 7) and are compatible with each other. Also check to ensure the torque is correct for the cap size being used (refer to page 8).
4.
Start unit, set the Output % to minimum and run a single container. Check the container for a seal.
5.
If no seal was achieved, increase the Output % in increments of 5-10% until a partial seal is achieved, increment by 1-2% until a complete seal is achieved (refer to page 9). If a partial seal was achieved, increase the Output % in increments of 1-2% until a complete seal is achieved (refer to page 10). This is the minimum set point of the Operating Window.
6.
Once the minimum set point is established, increase the Output % by 1-2% until the liner or cap show signs of overheating (refer to page 9). Decrease Output by 1% until the overheating is eliminated. This is the maximum set point of the Operating Window.
7.
Now that the Operating Window is established test the package in the range of Output from minimum to maximum to determine at what Output % the best seal is achieved. This will be the production Output level.
8.
Position and run a tightly grouped number of containers that will completely fill the Sealing Head. Verify the Output % on the meter remains constant and that the seal results are the same on all containers run.
9.
Record the Minimum/Maximum Output % of the Window, Production Output %, Line Speed, Cap, Liner and Container information for future reference. Your Operations Manual includes a Production Information table for this purpose.
10. Repeat all steps for each package run on the equipment.
This information is a useful tool that helps decrease the time required for changeover between packages, as well as troubleshooting to help determine if you have a package or equipment problem.
11 Enercon Industries Corporation
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web: www.enerconind.com
email: [email protected]
Super Seal™ Troubleshooting Tips Symptom AUTO O LED Lit and Output Only 25% Display Dim Or Flickers While Unit Is Running. Unit Runs But RUN LED Is Not Lit. REMOTE LED Lit And None Of The Buttons Function. TEMP LED Is Lit.
FAULT LED Is Lit
AUTO O LED Lit With No Control Over Changing Function. Display Stops Flashing, And Shows A Solid 00 On Output.
Cause
Solution
1. AUTO Mode Option Not Included With Unit. 2. Unit Waiting For 0-10V Signal From PLC. 1. Output Capacitor Cable Incorrectly Routed. 2. Output Capacitor Body Isolated From Ground. 1. The Output Level Is Below The Adjustable LSI Set Point (If Unit Has A Stack Light It Will Flash Red). 1. Improperly Installed Control / Display Board. 2. 1. 2. 3. 4.
Failed Control / Display Board. Ambient Temperature Too High. Dirty / Failed Cooling Fan. Failed Temperature Sensor. Failed Control / Display Board.
1. 2. 3. 4.
Failed Inverter. Failed Power Connector Board. Failed Control / Display Board. Input Voltage Too Low – 208 VAC Or Lower Input Voltage On A 240 VAC System.
1. Failed Control / Display Board. 2. Improperly Installed Control / Display Board. 1. 2. 3. 4.
Interlocks Not Satisfied. Defeat Plugs Or Sensors Not Connected. Failed Inverter. Open Output.
5. In Remote Mode – Waiting On Remote Start Command (R REMOTE E LED Is Lit).
1. Switch To MAN Mode. 2. Provide 0-10V Signal. 1. Loosen Nut Securing Wire #48, Rotate Wire Away From Display Board. 2. Snug Capacitor Mounting Hardware The Solder Plugs On All Capacitor Bodies Read Shorted To Base Plate. 1. Refer To Your Operations Manual To Ensure LSI Setpoint Level Is Set Properly. 1. Reinstall Control / Display Board Ensuring All Buttons Depress And Release Properly. 2. Repair / Replace Control / Display Board. 1. Ensure Ambient Temperature 104º F/40º C. 2. Clean / Replace Cooling Fans. 3. Check / Replace Sensor. 4. Repair / Replace Control / Display Board. 1. Perform Inverter Ohm Checks, Replace Inverter. 2. Repair / Replace Power Connector Board. 3. Repair / Replace Control / Display Board. 4. Step Up 208 VAC Using Buck/Boost Or Input Transformer Or Supply Input Voltage From A 240 VAC Source. 1. Repair / Replace Control / Display Board. 2. Reinstall Control / Display Board Ensuring All Buttons Depress And Release Properly. 1. Check Interlocks / Connections. 2. Ensure Defeat Plugs / Sensors Are Installed Properly. 3. Perform Inverter Ohm Checks, Replace Inverter. 4. Check Output Wiring To Output Caps, Ct And Sealing Head. 5. Change To Manual Mode Or Provide Remote Start.
Super Seal™ Max / Super Seal™ Deluxe Troubleshooting Tips Symptom
Cause
Solution
Turn Breaker On And / Or Ensure Proper Input Voltage. Reconnect / Replace Ribbon Cable. VFD Display Does Repair / Replace Display Board. Not Light Up Repair / Replace Control Board. Ready Indicator Lit, Ensure Proper Voltage Is Supplied. But Dim. Repair / Replace Control Board. Remove / Isolate Metal. Ensure Input Power Is Correct And Steady. Output Fluctuates Ensure Sealing Head Is Connected Securely. (More Than 2%). Repair / Replace Control Board. Replace Inverter. Inverter Fault. Repair / Replace Control Board. Check Ambient Temperature. Clean / Replace Cooling Fan. Temperature Fault. Check Wiring / Replace Temp. Sensor. Repair / Replace Control Board. Repair / Replace Sealing Head. Replace Output Capacitors (All Caps). Over Current Fault. Repair / Replace Output Current Transformer. Tighten / Replace Wiring. Interlock Fault Close Interlock, Install Defeat Connector. System Error Refer To Operations Manual For System Error Message Description. 1. Ribbon Cable. 1. Reconnect / Replace Ribbon Cable. Communication 2. Display Board. 2. Repair / Replace Display Board. Error Message 3. Control Board. 3. Repair / Replace Control Board. NOTE: For symptoms not listed on table contact Enercon Industries Customer Service (262) 255-6070. 1. Circuit Breaker / Input Voltage. 2. Ribbon Cable. 3. Failed Display Board. 4. Failed Control Board. 1. Low Input Voltage. 2. Control Board. 1. Sealing Head Coupling Into Nearby Metal. 2. Inadequate Input Power. 3. Sealing Head Connections. 4. Failed Control Board. 1. Inverter 2. Control Board. 1. Over Temperature. 2. Cooling Fan. 3. Temperature Sensor. 4. Control Board. 1. Sealing Head. 2. Output Capacitors. 3. Output Current Transformer. 4. Loose Wiring. 1. Open Interlock. 1. System Has Experienced An Internal Error.
1. 2. 3. 4. 1. 2. 1. 2. 3. 4. 1. 2. 1. 2. 3. 4. 1. 2. 3. 4. 1. 1.
12 Enercon Industries Corporation
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Compak™ / Compak™ Convertible / Integral II / Early Super Seal™ Troubleshooting Tips Symptom
Front Panel LEDs
FAULT
STANDBY FAULT
Meter
00
Bd LED N/A
Seal
Cause 1. 2. 3. 4.
No Seal
Water Hoses Reversed. Low Water Pressure. Pressure Switch. Failed Control Board.
1. Failed Inverter / Chopper. GEN
STANDBY GEN
TEMP
STANDBY TEMP
Power Supply Will Not Start
None
00
Lit
00
N/A
00
N/A
2. 3. 4. 5.
No Seal
No Seal
No Seal
Failed Control Board. Failed Output Capacitor. Failed Sealing Head. Failed Output Leads.
Solution 1. 2. 3. 4.
Swap Hoses. Check Water Level And Strainer. Check Wiring / Replace Switch. Repair / Replace Control Board.
1. Replace Device And Gate Leads. 2. Repair / Replace Control Board. 3. Replace All Capacitors. 4. Replace Sealing Head. 5. Replace Output Leads
1. Insufficient Cooling Water Or Air Flow. 2. Failed Temp Switch. 3. Failed Control Board.
1. Check Water System And Cooling Fan. 2. Replace Temp Switch. 3. Repair/Replace Control Board.
1. Input Power Missing. 2. Ribbon Cable.
3. Failed Control Board. 4. Miswiring In Power Supply.
1. Check Voltage Source. 2. Connect / Replace Ribbon Cable. 3. Replace Circuit Breaker. 4. Repair / Replace Control Board. 5. Repair / Replace Membrane Switch. 1. Check Interlocks / Connections. 2. Repair / Replace Membrane Switch. 3. Repair / Replace Control Board. 4. Correct Wiring.
3. Failed Circuit Breaker. 4. Failed Control Board. 5. Failed Membrane Switch. 1. Interlocks Not Satisfied. 2. Failed Membrane Switch.
Power Supply Will Not Start
STANDBY
Power Supply Will Not Start
STANDBY
02 to 06
Lit
No Seal
1. Failed Inverter / Chopper. 2. Failed Control Board.
1. Replace Failed Device. 2. Repair / Replace Control Board.
Power Supply Will Not Start
STANDBY
07 to 12
Lit
No Seal
1. Defective Output Capacitor.
1. Replace All Output Capacitors.
00
N/A
No Seal
1. Remove / Isolate Metal.
STANDBY RUN
1. Sealing Head Coupling Into Nearby Metal. Lit If May Not Be 2. Inadequate Input Power. 25% to
Why Enercon? Variety Enercon Has The Largest Range Of Air-Cooled Induction Cap Sealing Systems Available In The Industry Today, With 8 Models And Multiple Configurations To Suit Your Specific Needs.
Air-cooled Systems Table Top
Conveyor Mount
Specialty / Capless
Auto Jr.
Super Seal™ (SS50 – SS100)
Pneumatic Jr.
Super Seal™ Jr.
Super Seal™ Deluxe
Rotary / Indexing
Super Seal™ Max
Pressure Belt
Tunnel Sealing Head Design Enercon’s unique tunnel sealing head design (offered as standard for 53mm closures and smaller) increases electromagnetic power coupling into the foil, resulting in greater sealing efficiency. This greater efficiency permits faster line speeds at an equal power level.
Outstanding Service Enercon stands behind our equipment and customers with 24-hour technical assistance, rapid parts shipment, as well as loaner and exchange programs. Our worldwide network of representatives provides local expertise both before and after the sale. For immediate assistance online go to: www.enerconind.com/support..
Selecting the Right Induction Sealing System Questions to Answer With Cap
Capless
1. 2. 3. 4. 5. 6.
Type of Product? Temperature of Product? Size of Container? Container Material? Diameter of Cap? Style of Cap: Child-Resistant, Dispensing, Snap Cap, Standard Flat, Push/Pull, Flip-Top? 7. Liner Material? 8. Conveyor Speed (Feet or Meters per Minute)? 9. Is Wash Down Required?
1. 2. 3. 4. 5. 6. 7. 8.
Type of Product? Temperature of Product? Diameter of Container Opening? Size of Container? Container Material? Liner Material? Inline, Rotary or Indexing Production Line? Line Speed (Bottles per Minute – Rotary & Indexing, Feet or Meters per Minute – Pressure Belt)?
Induction Sealing Rules Of Thumb Glass containers with dry product can always be sealed. Check with your inner seal supplier when sealing liquids in glass. The induction sealing process is still effective when liquid product is on the container lip, with the exception of some liquids on glass containers. The operating frequency of the power supply determines the heating pattern of the electromagnetic field. Higher frequency results in heat concentration on the outside edge of the inner seal, which is beneficial for the one-piece type liners. As the frequency is lowered, the heating tends to be more uniform across the inner seal. This is desirable for a wax-bonded type 2-piece inner seal. Electromagnetic radiation of the type and power level used is not harmful to humans.
1 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Service Options Startup Made Easy Enercon offers a discounted Startup service for our customers who are unfamiliar with the installation and use of induction cap sealing equipment. As part of the service, an experienced Enercon Field Service Engineer will review your cap sealer installation, making sure that everything has been done correctly. Or, if you prefer, the Field Service Engineer can supervise your installation of the cap sealing system. Once your cap sealing system is up and running, the Field Service Engineer will provide hands-on training for your operators, as well as training on routine preventive maintenance and troubleshooting for your maintenance personnel.
Preventive Maintenance Routine Preventive Maintenance is at the heart of every successful manufacturing operation. Our experience over the past 30 years has shown that an aggressive preventive maintenance program is the best insurance against downtime. Solid periodic maintenance will also prolong the life of your equipment. We have in place a preventive maintenance program, our PMV service, which is designed to give you that insurance. At a discounted rate we will supply a Field Service Engineer who will review all of your Enercon equipment. In addition to ensuring that your Enercon induction cap sealing systems are tuned up and performing correctly, our Field Service Engineer will provide hands-on training for your operators and maintenance personnel. He will also identify critical spare parts which should be a part of your maintenance inventory and help you refine your ongoing maintenance program. To learn more about our Startup and Preventive Maintenance visits, contact Paul Reed at (262) 2556070, or e-mail him at [email protected] He is ready to tell you more about these valuable programs and provide you with a comprehensive pricing package.
Field Service In conjunction with our Startup and PMV service, Enercon also provides emergency field service that gets consistently high ratings from our customers in the packaging industry. When a problem cannot be resolved by your maintenance department we will provide a Field Service Engineer to come to your plant and repair your equipment. With extensive hands-on experience and direct access to our Engineering Department, our Field Service Engineer will ensure that the problem you are experiencing is resolved. He will also determine if anything else in the system may require repair. For more information on Field Service visits contact Paul Reed at (262) 255-6070, or e-mail him at [email protected]
International Service Check with your local representative for the availability of International Field Service.
3 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Laboratory Policies And Procedures In-House Testing Enercon’s Induction Cap Sealing Laboratory can help you determine the proper sealing head and power rating, as well as test the suitability of your cap, bottle and liner material for your particular application. The lab has available every model, power rating and sealing head that Enercon manufactures, in order to duplicate actual production line conditions accurately. Equipment research and development, and applications testing, are continuously conducted in the laboratory. This is an important element in Enercon’s commitment to supply you with technological leadership in the constantly changing packaging industry.
Induction Cap Sealing Trials Enercon’s Induction Cap Sealing Laboratory is equipped with a conveyor and tachometer to reproduce your line speed requirements accurately. The laboratory is also equipped with all of the current production models of cap sealing equipment, as well as all of the standard and specialty sealing heads produced by Enercon. Tests can be performed on all sizes of containers and caps, from a small tube to a 2-gallon jug, with caps from 5mm to 120mm and larger. As a result of our cooperation with the leading liner material manufacturers, the laboratory also has a supply of practically all liner materials that are available. Therefore, we can work with the liner material you have already selected or refer you to the liner material manufacturers who can help you select the material that is best for your application. The laboratory is also equipped with a Pack-Vac Leak Detector and a torque meter. The Leak Detector can accommodate all but the largest containers, for testing the hermetic seal strength, and the torque meter allows the testing of the application and removal torque. COST:
There is no charge for the test itself. We do request that you contact our Sales Department for an RCN (Return Control Number) and send your samples to our facility freight prepaid. Let us know if you would like your samples returned to you.
RESULTS:
You are welcome to visit our facility and observe the running of your sample. We will arrange to have your samples available at the time you wish to visit. Typically the visit would last three to five hours, usually from 9 a.m. until 2 p.m., with a break for lunch. You will be given a demonstration of the procedures followed for your sample. After a thorough discussion of your application, you are welcome to take a tour of the facilities and meet with members of our engineering staff to answer any technical questions you may have.
DATA SHEET:
If you are unable to visit, the results of your sample will be forwarded to you. Any questions you may have are welcomed by our Sales Engineers.
TIME:
Your sample will be tested in a timely manner, generally within one to two weeks.
4 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Seal Problem Troubleshooting Tips Symptom
Partial seal, weak seal, no seal.
Probable Cause
Possible Solution
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 treated with flame, corona, or chemically. f. Imperfections in container finish, land area.
a. See Page 11 for Operating Window Setup Procedure. b. See Page 10 for Sealing Head Alignment. c. See Page 8 for Suggested Application Torque. d. Contact your supplier, or send samples for testing. e. Contact your supplier.
g. Product is touching liner, heat sink effect. Seal extremely difficult to remove (1piece liner).
Cap extremely difficult to remove (2piece liner).
a. Power from sealer set too high.
a. See Page 11 for Operating Window Setup Procedure. b. Ensure line speed is correct. See Page 11 for Operating Window Setup Procedure.
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.
e. Product touching liner, heat sink effect.
Burnt Cardboard Liner.
Low or no removal torque.
Pinholing.
Pinwheel effect on liner.
f. See Page 7 to help identify problem, contact container manufacturer. g. Check the fill level of product.
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. See Page 11 for Operating Window Setup Procedure. b. See Page 10 for Sealing Head Alignment. c. See Page 8 for suggested application torque. d. See Page 11 for Operating Window Setup Procedure. Material in cap and backing material on liner may be too compatible – contact your supplier. e. Check the fill level of product. a. See Page 11 for Operating Window Setup Procedure. b. See Page 10 for Sealing Head Alignment, check for cocked cap. Do not stop conveyor while unit is still running. c. See Page 8 for suggested application torque or contact your supplier. d. Contact your supplier.
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. See Page 8 for suggested application torque.
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. See Page 11 for Operating Window Setup Procedure. b. Contact your supplier or send samples for testing.
a. Retorquing too soon after induction sealer.
a. Move Retorquing equipment further downstream from sealer. b. See Page 11 for Operating Window Setup Procedure.
b. Wax was not completely.
absorbed
into
pulpboard
b. See Page 8 for suggested application torque. c. Contact your Sales Manager to discuss possible solutions.
5 Enercon Industries Corporation
(262) 255-6070
web: www.enerconind.com
email: [email protected]
Liner Types Before Cap Is Applied To Container And Induction Sealed
Multilayer Liners Multilayer liners consist of 4 basic components, as shown.
C
B
A Pulpboard
Foil
Wax
D Polymer
B
A
Wax
Pulpboard After Cap Is Applied To Container And Induction Sealed
C Foil
When a multilayer liner passes through the induction field of the sealing head the following occurs:
D
1. The foil is heated to a temperature that will allow the polymer to melt and flow. 2. The polymer flows around the land area of the container filling any voids. 3. The wax is melted and absorbed into the pulpboard, or similar absorbent material. 4. The polymer cools and hardens creating the hermetic seal.
Polymer
Before Cap Is Applied To Container And Induction Sealed
Single-Piece Liners Single piece liners consist of 2 basic components, as shown.
A
B Polymer
Foil
When a single-piece liner passes through the induction field of the sealing head the following occurs:
After Cap Is Applied To Container And Induction Sealed
A Foil
1. The foil is heated to a temperature that will allow the polymer to melt and flow. 2. The polymer flows around the land area of the container filling any voids. 3. The polymer cools and hardens creating the hermetic seal.
B Polymer
6 Enercon Industries Corporation
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email: [email protected]
Cap / Container Issues Good Container Lip/Liner Contact Good contact between the liner material and the container lip is very important. This goes hand in hand with the amount of torque applied, but can be a problem even when the torque levels are good. The land area of the container should be wide enough and rigid enough to support the pressures and heating required for a good seal.
Poor Container Lip/Liner Contact A thin or weak land area can cause poor contact between the liner material and the container lip. When the land area is too thin there may not be enough rigidity in the land area to support the pressures and heat required for a good seal.
Container Lip Deformations Gaps between the land area and liner material can be the result of any number of problems, from mold imperfections to container material issues. Regardless of the cause, any gap between the liner and container land area may cause overheating and failure of the seal. A gap caused by fall away of the land area, as well as a gap caused by a protrusion, is shown. These defects can typically be detected on the container land area before the container is capped.
Cocked Cap A cocked cap is usually due to a problem with the capping process or a cap or container problem. The gap created can cause overheating and the cap itself may actually jam the container under the sealing head causing the liner to overheat severely.
7 Enercon Industries Corporation
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email: [email protected]
Torque Requirements One of the most common causes of poor or inconsistent sealing is an improperly torqued cap. Whether the torque is too low or too high, the end result is usually an air gap between the lip of the container and the liner material. This air gap will usually cause overheating of the liner, but at the very least will create a gap too large for the polymer to fill. The following table is provided as a general rule of thumb for determining the torque required for your cap size. For exact torque requirements, contact your cap manufacturer.
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 (.79-1.13nm) 8-12 in./lbs (.9-1.35nm) 9-14 in./lbs (1-1.58nm) 10-16 in./lbs (1.13-1.8nm) 12-18 in./lbs (1.35-2.03nm) 15-25 in./lbs (1.69-2.82nm) 17-26 in./lbs (1.92-2.93nm) 18-27 in./lbs (2.03-3.05nm) 19-30 in./lbs (2.14-3.38nm)
53mm 58mm 63mm 70mm 83mm 89mm 100mm 110mm 120mm
21-36 in./lbs (2.37-4.06nm) 23-40 in./lbs (2.59-4.51nm) 25-43 in./lbs (2.82-4.85nm) 28-50 in./lbs (3.16-5.65nm) 40-60 in./lbs (4.51-6.78nm) 45-65 in./lbs (5.08-7.34nm) 50-70 in./lbs (5.65-7.90nm) 52-73 in./lbs (5.87-8.25nm) 55 -75 in./lbs (6.21-8.47nm)
8 Enercon Industries Corporation
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Liner Issues
Good Seal A good seal will have good adhesion for the entire circumference of the bottle opening. Wrinkling will be at a minimum and on multilayer liners the cap will have no darkening that would indicate overheating. No o discoloration n indicatess properr outputt level..
Poor Seal When the output is too low, line speeds too high, or the sealing head misaligned the liner material will not adhere properly to the lip of the bottle. This can range from a seal that lets go under light pressure to no adhesion to the lip of the bottle. On multilayer liners there may also be swirling of the liner due to poor wax absorption into the backing material.
Overheated Seal When the output is too high, or line speeds too slow, overheating of the liner will occur. The liner will often wrinkle badly, melt into the lip of the bottle, and give off a burned smell. The burned smell can also contaminate your product. On multilayer liners the pulpboard will show signs of discoloration or burning, depending on the severity of the overheating.
Darkening g orr burning g indicatess outputt levell needss to o be e lowered.
Easy-Peel Liners Easy-peel liners seal tightly to the lip of the bottle, but allow for a clean peel from the bottle.
Tamper-Evident Liners Tamper-evident liners seal tightly to the lip of the bottle, but leave part of the liner on the lip when opened. This is used to show evidence that the bottle has indeed been opened.
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(262) 255-6070
web: www.enerconind.com
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Sealing Head Alignment Tunnel Sealing Head
Flat Sealing Head
Deep Tunnel Sealing Head The Liner Must Be Aligned As Shown
1 8'
To 14' Gap (3 To 6mm)
SIDE VIEW
FRONT VIEW READY RUN REMOTE AUTO AUTO
REMOTE
TUNNEL SEALING HEAD
SETUP
SELECT
SCROLL
DONE
START
STOP
Super Seal ™ Deluxe
FLAT SEALING HEAD
'D'
1 8' GAP RECOMMENDED
'D'
'D'
CONVEYOR
'D'
CONVEYOR
NOTE: 'D' (Distance) Must Be Equal Side To Side And Back To Front Above Conveyor For Optimum Performance Of Sealing Head.
Sealing Head Alignment Quick Setup Step 1:
Level and center Sealing Head over conveyor or product.
Step 2:
Fill 2 containers with product to duplicate production weight.
Step 3:
Place one container at each end of the Sealing Head.
Step 4:
Place a proper thickness gauge on top of each cap.
Step 5:
Lower the Sealing Head onto the gauge. The fit should be snug with no change to gap when the gauge is removed.
Step 6:
Align guide rails to ensure the containers enter and exit the Sealing Head properly centered.
Note: The “1” Sealing Head should be initially set up like the Flat Sealing Head and then skewed to the proper position for the cap size being sealed. Ensure there are no metal guide rails located beneath the sealing head.
Setup Information We recommend that a record be kept of the setup information for each product run with your Cap Sealer. This information helps ensure consistent and accurate change over between products. This information also helps troubleshooting of sealing issues if they arise. The Miscellaneous Section in your manual contains a table for recording this information.
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Operating Window Setup Procedure As with any piece of equipment it is important to know your Cap Sealer’s operating parameters. The following is a step-by-step explanation of how to determine the Operating Window for each package run on a given piece of equipment. 1.
Ensure the unit is installed properly (refer to your Operations Manual) and the sealing head is at the correct height, centered, and is parallel over the conveyor (refer to Page 10).
2.
Ensure the conveyor speed is set properly for the package being tested.
3.
Ensure the container and caps are free of defects (refer to page 7) and are compatible with each other. Also check to ensure the torque is correct for the cap size being used (refer to page 8).
4.
Start unit, set the Output % to minimum and run a single container. Check the container for a seal.
5.
If no seal was achieved, increase the Output % in increments of 5-10% until a partial seal is achieved, increment by 1-2% until a complete seal is achieved (refer to page 9). If a partial seal was achieved, increase the Output % in increments of 1-2% until a complete seal is achieved (refer to page 10). This is the minimum set point of the Operating Window.
6.
Once the minimum set point is established, increase the Output % by 1-2% until the liner or cap show signs of overheating (refer to page 9). Decrease Output by 1% until the overheating is eliminated. This is the maximum set point of the Operating Window.
7.
Now that the Operating Window is established test the package in the range of Output from minimum to maximum to determine at what Output % the best seal is achieved. This will be the production Output level.
8.
Position and run a tightly grouped number of containers that will completely fill the Sealing Head. Verify the Output % on the meter remains constant and that the seal results are the same on all containers run.
9.
Record the Minimum/Maximum Output % of the Window, Production Output %, Line Speed, Cap, Liner and Container information for future reference. Your Operations Manual includes a Production Information table for this purpose.
10. Repeat all steps for each package run on the equipment.
This information is a useful tool that helps decrease the time required for changeover between packages, as well as troubleshooting to help determine if you have a package or equipment problem.
11 Enercon Industries Corporation
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Super Seal™ Troubleshooting Tips Symptom AUTO O LED Lit and Output Only 25% Display Dim Or Flickers While Unit Is Running. Unit Runs But RUN LED Is Not Lit. REMOTE LED Lit And None Of The Buttons Function. TEMP LED Is Lit.
FAULT LED Is Lit
AUTO O LED Lit With No Control Over Changing Function. Display Stops Flashing, And Shows A Solid 00 On Output.
Cause
Solution
1. AUTO Mode Option Not Included With Unit. 2. Unit Waiting For 0-10V Signal From PLC. 1. Output Capacitor Cable Incorrectly Routed. 2. Output Capacitor Body Isolated From Ground. 1. The Output Level Is Below The Adjustable LSI Set Point (If Unit Has A Stack Light It Will Flash Red). 1. Improperly Installed Control / Display Board. 2. 1. 2. 3. 4.
Failed Control / Display Board. Ambient Temperature Too High. Dirty / Failed Cooling Fan. Failed Temperature Sensor. Failed Control / Display Board.
1. 2. 3. 4.
Failed Inverter. Failed Power Connector Board. Failed Control / Display Board. Input Voltage Too Low – 208 VAC Or Lower Input Voltage On A 240 VAC System.
1. Failed Control / Display Board. 2. Improperly Installed Control / Display Board. 1. 2. 3. 4.
Interlocks Not Satisfied. Defeat Plugs Or Sensors Not Connected. Failed Inverter. Open Output.
5. In Remote Mode – Waiting On Remote Start Command (R REMOTE E LED Is Lit).
1. Switch To MAN Mode. 2. Provide 0-10V Signal. 1. Loosen Nut Securing Wire #48, Rotate Wire Away From Display Board. 2. Snug Capacitor Mounting Hardware The Solder Plugs On All Capacitor Bodies Read Shorted To Base Plate. 1. Refer To Your Operations Manual To Ensure LSI Setpoint Level Is Set Properly. 1. Reinstall Control / Display Board Ensuring All Buttons Depress And Release Properly. 2. Repair / Replace Control / Display Board. 1. Ensure Ambient Temperature 104º F/40º C. 2. Clean / Replace Cooling Fans. 3. Check / Replace Sensor. 4. Repair / Replace Control / Display Board. 1. Perform Inverter Ohm Checks, Replace Inverter. 2. Repair / Replace Power Connector Board. 3. Repair / Replace Control / Display Board. 4. Step Up 208 VAC Using Buck/Boost Or Input Transformer Or Supply Input Voltage From A 240 VAC Source. 1. Repair / Replace Control / Display Board. 2. Reinstall Control / Display Board Ensuring All Buttons Depress And Release Properly. 1. Check Interlocks / Connections. 2. Ensure Defeat Plugs / Sensors Are Installed Properly. 3. Perform Inverter Ohm Checks, Replace Inverter. 4. Check Output Wiring To Output Caps, Ct And Sealing Head. 5. Change To Manual Mode Or Provide Remote Start.
Super Seal™ Max / Super Seal™ Deluxe Troubleshooting Tips Symptom
Cause
Solution
Turn Breaker On And / Or Ensure Proper Input Voltage. Reconnect / Replace Ribbon Cable. VFD Display Does Repair / Replace Display Board. Not Light Up Repair / Replace Control Board. Ready Indicator Lit, Ensure Proper Voltage Is Supplied. But Dim. Repair / Replace Control Board. Remove / Isolate Metal. Ensure Input Power Is Correct And Steady. Output Fluctuates Ensure Sealing Head Is Connected Securely. (More Than 2%). Repair / Replace Control Board. Replace Inverter. Inverter Fault. Repair / Replace Control Board. Check Ambient Temperature. Clean / Replace Cooling Fan. Temperature Fault. Check Wiring / Replace Temp. Sensor. Repair / Replace Control Board. Repair / Replace Sealing Head. Replace Output Capacitors (All Caps). Over Current Fault. Repair / Replace Output Current Transformer. Tighten / Replace Wiring. Interlock Fault Close Interlock, Install Defeat Connector. System Error Refer To Operations Manual For System Error Message Description. 1. Ribbon Cable. 1. Reconnect / Replace Ribbon Cable. Communication 2. Display Board. 2. Repair / Replace Display Board. Error Message 3. Control Board. 3. Repair / Replace Control Board. NOTE: For symptoms not listed on table contact Enercon Industries Customer Service (262) 255-6070. 1. Circuit Breaker / Input Voltage. 2. Ribbon Cable. 3. Failed Display Board. 4. Failed Control Board. 1. Low Input Voltage. 2. Control Board. 1. Sealing Head Coupling Into Nearby Metal. 2. Inadequate Input Power. 3. Sealing Head Connections. 4. Failed Control Board. 1. Inverter 2. Control Board. 1. Over Temperature. 2. Cooling Fan. 3. Temperature Sensor. 4. Control Board. 1. Sealing Head. 2. Output Capacitors. 3. Output Current Transformer. 4. Loose Wiring. 1. Open Interlock. 1. System Has Experienced An Internal Error.
1. 2. 3. 4. 1. 2. 1. 2. 3. 4. 1. 2. 1. 2. 3. 4. 1. 2. 3. 4. 1. 1.
12 Enercon Industries Corporation
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Compak™ / Compak™ Convertible / Integral II / Early Super Seal™ Troubleshooting Tips Symptom
Front Panel LEDs
FAULT
STANDBY FAULT
Meter
00
Bd LED N/A
Seal
Cause 1. 2. 3. 4.
No Seal
Water Hoses Reversed. Low Water Pressure. Pressure Switch. Failed Control Board.
1. Failed Inverter / Chopper. GEN
STANDBY GEN
TEMP
STANDBY TEMP
Power Supply Will Not Start
None
00
Lit
00
N/A
00
N/A
2. 3. 4. 5.
No Seal
No Seal
No Seal
Failed Control Board. Failed Output Capacitor. Failed Sealing Head. Failed Output Leads.
Solution 1. 2. 3. 4.
Swap Hoses. Check Water Level And Strainer. Check Wiring / Replace Switch. Repair / Replace Control Board.
1. Replace Device And Gate Leads. 2. Repair / Replace Control Board. 3. Replace All Capacitors. 4. Replace Sealing Head. 5. Replace Output Leads
1. Insufficient Cooling Water Or Air Flow. 2. Failed Temp Switch. 3. Failed Control Board.
1. Check Water System And Cooling Fan. 2. Replace Temp Switch. 3. Repair/Replace Control Board.
1. Input Power Missing. 2. Ribbon Cable.
3. Failed Control Board. 4. Miswiring In Power Supply.
1. Check Voltage Source. 2. Connect / Replace Ribbon Cable. 3. Replace Circuit Breaker. 4. Repair / Replace Control Board. 5. Repair / Replace Membrane Switch. 1. Check Interlocks / Connections. 2. Repair / Replace Membrane Switch. 3. Repair / Replace Control Board. 4. Correct Wiring.
3. Failed Circuit Breaker. 4. Failed Control Board. 5. Failed Membrane Switch. 1. Interlocks Not Satisfied. 2. Failed Membrane Switch.
Power Supply Will Not Start
STANDBY
Power Supply Will Not Start
STANDBY
02 to 06
Lit
No Seal
1. Failed Inverter / Chopper. 2. Failed Control Board.
1. Replace Failed Device. 2. Repair / Replace Control Board.
Power Supply Will Not Start
STANDBY
07 to 12
Lit
No Seal
1. Defective Output Capacitor.
1. Replace All Output Capacitors.
00
N/A
No Seal
1. Remove / Isolate Metal.
STANDBY RUN
1. Sealing Head Coupling Into Nearby Metal. Lit If May Not Be 2. Inadequate Input Power. 25% to
Enercon Super Seal Max
Enercon Super Seal Manual
Enercon Super Seal 75 Manual Diagram
- Enercon Has The Largest Range Of Air-Cooled Induction Cap Sealing Systems Available In The Industry Today, With 8 Models And Multiple Configurations To Suit Your Specific Needs. Air-cooled Systems Table Top Conveyor Mount Specialty / Capless Auto Jr. Super Seal™ (SS50 – SS100) Pneumatic Jr. Super Seal™ Jr. Super Seal™ Deluxe Rotary.
- Enercon Industries is the world-leading supplier of induction cap sealing and surface treatment technology across the globe. Over the past 40 years, we have been helping manufacturers improve their manufacturing processes resulting in higher productivity, lower unit costs, increased recyclability, reduced wastage and operating costs.