Instruction Manual

CS 200SS Standard

Sealing Head
Document No. 0010-0257 (IM) (Rev -)

 CS 200SS

PROPRIETARY INFORMATION NOTICE

This document contains information proprietary to Lepel Corporation. All rights

are reserved.

No part of this document may be reproduced, transmitted, processed or recorded

by any means or form, electronic, mechanical, photographic or otherwise, nor be
released to any third party without the express written consent of Lepel
Corporation.

2006 Lepel Corp.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) iii

 CS 200SS

Document Revision Status

REV DATE ENGR DESCRIPTION
- 06/08/06 JK Manual created and released

Instruction Manual Document No. 0010-0257 (IM) (Rev -) v

 CS 200SS

Table of Contents

DOCUMENT REVISION STATUS .........................................................................................................................V

PREFACE ................................................................................................................................................................. IX

CONTACTS.............................................................................................................................................................. XI

PRODUCT DIVERSITY ......................................................................................................................................... XI

SECTION 1: INTRODUCTION ........................................................................................................................1

1.1 PURPOSE OF THIS MANUAL ................................................................................................................................1
1.2 AUDIENCE .........................................................................................................................................................1
1.3 MANUAL ORGANIZATION ...................................................................................................................................1
1.4 MANUAL CONVENTIONS ....................................................................................................................................2

SECTION 2: DESCRIPTION.............................................................................................................................3
2.1 GENERAL ...........................................................................................................................................................3
2.2 MAJOR COMPONENTS .........................................................................................................................................3
2.2.1 Main Body ...............................................................................................................................................3
2.2.2 Coil ..........................................................................................................................................................3
2.2.3 Control/Display Panel.............................................................................................................................3
2.2.4 Cable and Connector...............................................................................................................................3
2.2.5 Heat-On Light..........................................................................................................................................3
2.2.6 Heat Sink Fins .........................................................................................................................................4
2.3 CONNECTIONS ...................................................................................................................................................4
2.3.1 6-Pin Connector ......................................................................................................................................4
2.4 ENCLOSURE .......................................................................................................................................................4
SECTION 3: INSTALLATION..........................................................................................................................7
3.1 INSTALLATION PROCEDURE ...............................................................................................................................7
3.2 UNPACKING .......................................................................................................................................................7
3.3 CONNECTING THE SEALING HEAD ......................................................................................................................7

SECTION 4: PREPARATION ...........................................................................................................................9

4.1 SEALING HEAD PREPARATION ............................................................................................................................9

SECTION 5: OPERATION ..............................................................................................................................11

5.1 THEORY OF OPERATION ...................................................................................................................................11
5.2 CONTROL PANEL/USER INTERFACE ..................................................................................................................12
5.2.1 Menu Structure ......................................................................................................................................12
5.2.1.1 Heat On Screen .................................................................................................................................14
5.2.1.2 Sealing Head Type ............................................................................................................................14
5.2.1.3 Power Control Screen .......................................................................................................................14
5.3 ALARMS, FAULTS AND WARNINGS ...................................................................................................................14
5.3.1 Phase Fault............................................................................................................................................14
5.3.2 Current Fault.........................................................................................................................................14

Instruction Manual Document No. 0010-0257 (IM) (Rev -) vii

Contents

5.3.3 Frequency Fault.................................................................................................................................... 14

5.3.4 Temperature Fault ................................................................................................................................ 15
5.3.5 Sealing Head Temp ............................................................................................................................... 15
5.3.6 Communication Fault ........................................................................................................................... 15
5.3.7 Power Alarm ......................................................................................................................................... 15
5.3.8 Auxiliary Fault...................................................................................................................................... 15
5.3.9 Power Overload.................................................................................................................................... 15
5.3.10 Int. Board Fault ................................................................................................................................ 15
SECTION 6: MAINTENANCE ....................................................................................................................... 17
6.1 SCHEDULING ................................................................................................................................................... 17
6.2 PERSONNEL ..................................................................................................................................................... 17
6.3 INSPECTION AND MAINTENANCE PROCEDURE ................................................................................................. 17
6.3.1 Daily and Weekly Inspection................................................................................................................. 17
6.3.2 Monthly Inspection................................................................................................................................ 17
6.4 SPARE PARTS .................................................................................................................................................. 18

viii Lepel Corporation

 CS 200SS

PREFACE
YOU AND NOT THIS MANUAL ARE RESPONSIBLE FOR ALL
SAFETY PRECAUTIONS

This manual is for reference purposes only. Personnel should be trained on

proper operation of this equipment before using. Only fully trained and
authorized personnel may perform any troubleshooting or repair on any Lepel
manufactured equipment. Failure to comply will void warranty.

Please contact the Lepel Service department before servicing any Lepel
equipment.

All information contained in this manual is the latest information available at the
time of printing. The right is reserved to make changes at anytime without notice.
LEPEL CORPORATION makes no warranty of any kind with regard to this
material and assumes no responsibility for any errors that may occur in this
manual.

Unless otherwise stated, references to Sealing Head or Coil in this manual refer to the
Lepel CS 200SS Standard Sealing Head.

WARNING
Lethal voltages may be present in equipment surrounding and/or connected to the CS
200SS Standard Sealing Head and Power Supply. Read the following warnings carefully
and study this entire manual before operating the system. Failure to observe warnings
may result in equipment damage, serious personal injury, or death.

If the equipment is used in a manner not specified by this manual, the protection provided
by the equipment may be compromised and damage to the unit may occur.

1. Only qualified persons who have been trained in the operation of the CS 200SS System
and are familiar with its technology should be permitted to operate the system.

2. Installation, assembly, inspection and maintenance, and servicing are to be performed by

fully trained and authorized personnel only.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) ix

Read This First!

3. Always have the energy unit completely powered off and locked out before connecting or
disconnecting the Sealing Head.

4. Always have the energy unit completely powered off and locked out before performing
any service, inspection or maintenance on the Sealing Head.

5. Always have the external power source that feeds the energy unit completely powered off
and locked out before performing any service, inspection or maintenance on the Sealing
Head.

6. Ensure that all external wiring conforms to applicable codes.

7. Obey all warnings and use good common sense.

x Lepel Corporation
 CS 200SS

Contacts

CORPORATION
200 Executive Dr. Suite G
Edgewood, N.Y. 11717
TEL (631) 586-3300
1-800-548-8520
FAX (631) 586-3232

CORPORATION
730 Larry Court
Waukesha, WI 53186
TEL (262) 782-0450
1-800-231-6008
FAX (262) 782-3299

24-Hour Technical Service Hotline

1-800-334-0441

Product Diversity
Lepel produces various styles of sealing heads and power supplies to help meet the different needs of
customers.
Single-phase and three-phase power supplies available
Different output powers available in single-phase connection
Standard type heads for typical flat cap sealing applications
Wide type heads for large cap sealing applications
Tunnel type heads for tall cap sealing applications or possibly to aid with speed issues

Call a Lepel representative to discuss your application and which products will suit your needs using the
Contact information listed above.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) xi

 CS 200SS

Section 1: Introduction

1.1 PURPOSE OF THIS MANUAL

This document is the operator manual for the Lepel CS 200SS Standard Sealing Head. It provides
installation, operation, inspection and maintenance, and troubleshooting procedures. Special emphasis
should be placed on all safety discussions.

1.2 AUDIENCE
This manual is written for personnel familiar with the technology pertaining to the operation of induction
sealing equipment. Such personnel should be thoroughly familiar with the hazards associated with this
equipment and electrical equipment in general, and they should have received proper safety procedure
training.

1.3 MANUAL ORGANIZATION

This manual contains:

Preface Discusses hazards and safety precautions.

Section 1: Introduction Identifies the purpose and organization of this
manual.
Section 2: Description Describes the operation and controls of the CS
200SS Standard Sealing Head.
Section 3: Installation Provides installation procedures.
Section 4: Preparation Preparation procedure prior to use.
Section 5: Operation Discusses theory of operation.
Section 6: Maintenance Provides instructions for periodic inspection and
maintenance.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 1

Section 1: Introduction

1.4 MANUAL CONVENTIONS

This manual uses the following conventions:

Bold indicates emphasis or a heading.

NOTE is used to set off important information from the rest of the text.

The manual also uses WARNINGs and CAUTIONs.

A WARNING symbol alerts you to a hazard that

may result in equipment damage, personal injury,
WARNING or death. Carefully read the instructions provided
and follow all safety precautions.

A CAUTION symbol alerts you that the system may

not operate as expected if instructions are not
CAUTION followed.

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 CS 200SS

Section 2: Description

2.1 GENERAL
The Lepel CS 200SS Standard Sealing Head is a self-contained RF output circuit designed to work in
conjunction with the CS 200SS Energy Unit to allow RF energy to be applied to a metal foil medium
allowing it to bond to a container.

The Sealing Head is enclosed in a stainless steel case, which helps reduce rust and oxidation while the
angled front allows better access to and visibility of the control panel.

2.2 MAJOR COMPONENTS

2.2.1 Main Body

The main body of the Sealing Head contains all the electrical components to produce the RF energy
necessary to heat foil seals. A temperature switch directly monitors the temperature of the internal
components and will shut down the attached Energy Unit should the Sealing Head components ever get
too hot.

2.2.2 Coil
The coil where the RF energy is produced is located on the bottom of the Sealing Head. The coil is fully
encapsulated to help protect it from the damages of everyday use. It measures approximately 654mm x
149mm (25.7 x 5.8).

2.2.3 Control/Display Panel

The Control/Display Panel is the user interface to the Sealing Head. It has five buttons, a 20-segment 2-
line LCD display and two indicator lights incorporated into a membrane style touch pad. This style of
interface is simple and easy to use while offering a non-obtrusive look and feel.

2.2.4 Cable and Connector

The control cable that connects the Sealing Head to the energy unit emerges from the back of the main
body beneath the mount and runs inside a length of corrugated tubing. The tubing allows flexibility and
mobility for the Sealing Head while protecting the wires from getting damaged. The cables terminate at a
10-pin connector that connects to the energy unit. The standard cable length is 5 with an optional 10
fixed extension length available.

2.2.5 Heat-On Light

The green light on the top of the Sealing Head is a Heat-On light. The light turns on when the Sealing
Head is producing RF energy.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 3

Section 2: Description

2.2.6 Heat Sink Fins

The heat sink fins are located at the rear of the unit. Since there is no forced air in the Sealing Head, the
heat generated by the internal components is dissipated through the fins. The Sealing Head is rated to run
in ambient temperatures up to 37C (100F).

2.3 CONNECTIONS

2.3.1 6-Pin Connector

There is a 6-pin connector on the back of the Sealing Head. It is accessible by reaching up underneath the
Sealing Head mounting bracket. This connector is for attaching and operating an optional light tower.

2.4 ENCLOSURE
The stainless steel enclosure has been designed with NEMA 4X and IP 65 standards in mind.

A NEMA 4X enclosure is intended for indoor or outdoor use primarily to provide a degree of protection
against corrosion, windblown dust and rain, splashing water and hose directed water; undamaged by ice
which forms on the enclosure.

An IP65 enclosure is one that is totally protected against dust and protected against low-pressure jets of
water from all directions with limited ingress allowed.

Height ~173.67 mm (6.83 inches)

Depth ~311 mm (12.24 inches)

Width ~707.5 mm (27.85 inches)

Weight ~28.4 kg (62.6 pounds)

4 Lepel Corporation
 CS 200SS

Figure 1: Illustration of CS 200SS Standard Sealing Head

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 5

 CS 200SS

Section 3: Installation

3.1 INSTALLATION PROCEDURE

The installation procedure consists of the following steps:

1. Unpacking the equipment.

2. Connecting the Sealing Head to the energy unit.

Power and ground/earth connections must be made

last. Failure to do so will create a hazardous
WARNING condition that may result in equipment damage,
personal injury, or death.

NOTE: Lepel Corporation has a staff of field engineers who are available to supervise the installation of
Lepel equipment. If installation service is required, contact the Lepel Technical Service
Department for additional information.

Provisions for facility electrical power service are customer furnished. Requesting Lepel field
engineering assistance before customer furnished provisions are installed at the equipment site
could delay equipment installation and cause unnecessary expense.

3.2 UNPACKING
Remove all packing materials. Carefully inspect the equipment and report any indication of damage to
the carrier immediately and advise your Lepel representative.

Inspect equipment before installing. Damaged

equipment may result in improper operation and
WARNING create a hazardous condition resulting in personal
injury or death.

All components were tested prior to shipment. The carrier is responsible for all damage caused in
shipment including concealed damage.

3.3 CONNECTING THE SEALING HEAD

The Sealing Head connects to the energy unit via a 10-pin connector. The connector is indexed and can
only be inserted one way. Make sure a positive click is felt when turning the locking collar to secure
the connector in place.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 7

 CS 200SS

Section 4: Preparation

4.1 SEALING HEAD PREPARATION

The Sealing Head requires no preparation before being used. Once attached to the energy unit, the
Sealing Head is ready to be used.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 9

 CS 200SS

Section 5: Operation

5.1 THEORY OF OPERATION

The Lepel CS 200SS Standard Sealing Head, with the aid of an energy unit, produces RF energy, which
can heat various types of metal depending on the material the metal is composed of and the thickness of
that material.

This process happens because the Sealing Head contains a capacitor and an inductor. This combination
of energy storage components produces a tank circuit. The main characteristic of a tank circuit is that
it resonates at a specific primary frequency depending on the values of the components. The formula for
this frequency is:

Freq = 1/(2(LC)), where L and C are the inductance and capacitance.

An example of this is shown in the following pictures. If a pulse is applied to a tank circuit, it will
resonate at a specific frequency. If left alone, the signal will decay to zero. If the circuit is energized
periodically at the correct time, the output will be a constant sinusoid.

When a foil lining or other metal object is brought within the RF field generated by the coil, eddy currents
will begin to circulate in the material and cause it to heat. Amplitude, frequency and coupling distance
between the load and the coil have a large effect on how well the RF field will heat the material.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 11

Section 5: Operation

5.2 CONTROL PANEL/USER INTERFACE

Display
UP & DOWN
MENU Buttons
Button
Alarm
Heat On Light
Light
START STOP
Button Button

Figure 2: Control Panel Keypad

5.2.1 Menu Structure

The flow chart for the Menu Structure is shown in Figure 3. The menu structure allows the user to get up
and running quickly by allowing the user to change the power setting at the first screen and begin running
the unit. When the Sealing Head is first powered up the display will briefly show the revision of the
Control Panel. Once that flash screen passes, the user will be at the menu structure, accessible by using
the MENU button.

Note: There are many intricacies in dealing with the sealing of bottles and tubes depending on the
materials used both for the container and the seal. The reader is urged to familiarize
themselves with the materials they are using to obtain the best seal possible. Other items
that may cause problems are:
- Incorrect cap torque: too much or too little
- Cocked cap
- Imperfections in the container finish
- Conveyor speed: too fast or too slow
- Aluminum foil thickness
- Thickness of wax layer
- Quality of backing: insufficient wax absorption
- Incompatibility between the liner and container material
- Coupling distance between the sealing head and the container: too much or too little
- Output power from the energy unit: too high or too low
- Misalignment of the cap under the sealing head

Using the MENU button, the user can easily cycle through the menu structure. This is shown
graphically below in a side-by-side view with both pictures and the flow chart, to aid the reader in using
the flow chart that appears later. What is shown below is only part of the menu structure.

12 Lepel Corporation
 CS 200SS

Graphic View Flow Chart View

The UP and DOWN arrows will change the From the Ready screen, pressing MENU
power setting. From the Ready screen, press will bring up the Type screen.
MENU.

This screen shows the type of Sealing Head,

which is automatically detected. (The UP and
DOWN arrows will show the revision levels From the Type screen, pressing MENU will
of the circuit boards.) From the Type screen, bring up the Power Control screen.
press MENU.

From the Power Control screen, press

MENU to return to the Ready screen.
From the Power Control screen, pressing
MENU will return the user to the Ready
screen.

The following is suggested to get a user up and running quickly. Set the conveyor line to the desired
speed. Setup the Sealing Head over the conveyor line with a coupling distance between the coil and
product to be heated/sealed of 3-4 mm (0.125). Set the Sealing Head so that the item to be heated/sealed
travels along the centerline of the coil, which can easily be seen by the triangular mark on the sides of the
Sealing Head.

The following shows a midpoint iterative process for achieving a proper power level setting. Set the
Sealing Head power level to 50% and run a sample. If it doesnt heat properly and needs more energy
change the power setting to 75% (this new setting being the midpoint between the 50% that was tried and
the top limit of 100%). Run another sample. Lets say this time the sample overheats. Continue the
midpoint process by choosing the midpoint between what was tried (75%) and the last good lower limit
(50%), namely 63%. Continue this process until the proper power lever is obtained.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 13

Section 5: Operation

5.2.1.1 Heat On Screen

From the Ready screen, if the START button is pushed, the Sealing Head will start producing RF
energy. This screen will show that the heat is on and the power level setting. If the MENU button is
pushed and held, the display will show the Primary Current in amps, the Primary Voltage in volts and the
percent the Sealing Head is being loaded.

5.2.1.2 Sealing Head Type

This screen displays the Sealing Head type.

Using the UP and DOWN buttons will allow the user to see the revision status of the circuit boards
within the Sealing Head and the attached energy unit.

5.2.1.3 Power Control Screen

This screen displays whether the method of power control is internal, namely the control panel on the
sealing, or external from another source. External power control can only be done using an Interface Box,
which is an optional item. Pressing the MENU button will bring up the Ready screen.

5.3 ALARMS, FAULTS AND WARNINGS

The following are possible alarms, faults and warnings that the user may encounter.

5.3.1 Phase Fault

The primary current and voltage of the energy unit are set in phase at the factory. This subjects the
semi-conductor devices to the least amount of stress and reduces heat build up and extends the life of the
devices. This fault results when the current and voltage fall out of phase enough to possibly cause
damage to the devices. Continued occurrence of this fault could be an indication of internal coil or
energy unit failure. Contact Lepel Service Department.

5.3.2 Current Fault

As a safety feature, the current that runs through the main output circuitry of the energy unit that supplies
energy to the Sealing Head is monitored. If that current exceeds a preset limit, a current fault condition
will occur. This fault can be indicative of a bad semi-conductor device or a possible short in the wiring.
Contact Lepel Service Department.

5.3.3 Frequency Fault

The Sealing Head and attached energy unit are programmed to run within a certain frequency range.
When the unit attempts to run outside the proper frequency range, a frequency fault is realized. A couple
of reasons for this could be a drastic change in the inductance of the attached coil or possibly a capacitor
that has gone bad. Contact Lepel Service Department.

14 Lepel Corporation
 CS 200SS

5.3.4 Temperature Fault

Making use of a temperature sensor on the heatsink of the energy unit, should the attached energy unit get
too hot, the unit will stop running and produce this fault. Allow the unit to cool before trying to run it
again. If the fault keeps occurring, make sure none of the cooling fins are blocked or obstructed. If
everything checks out well, contact Lepel Service Department.

5.3.5 Sealing Head Temp

The Sealing Head contains a temperature switch. Should the Sealing Head get too hot for any reason, the
unit will stop running and this fault will be displayed. Allow the head to cool before trying to run the unit
again. If the fault keeps occurring, make sure none of the fins on the back of the Sealing Head are
blocked or obstructed. If everything checks out well, contact Lepel Service Department.

5.3.6 Communication Fault

The Control Panel and the Control Board both have microprocessors, which need to communicate with
each other to work properly. This fault occurs if there is a loss of communications between these two
microprocessors. An unplugged cable or loose connection with the unit could be one cause of this.

5.3.7 Power Alarm

The energy unit attached to the Sealing Head houses a power board. This board contains a current inrush
limiting circuit that gets removed from the circuit a few moments after the START button is pushed on
the Sealing Head. That circuit is monitored and if it doesnt get removed after pressing START on the
Sealing Head, a Power Alarm fault is triggered. Should this continue to happen, contact Lepel Service
Department.

5.3.8 Auxiliary Fault

This fault will only be seen if the optional remote interface box is being used. There is a 2-terminal
Auxiliary Fault connection in the interface box that requires a dry-contact connection. Should the Sealing
Head be running and this Auxiliary connection be triggered, the unit will stop running and show the
Auxiliary fault.

5.3.9 Power Overload

The energy unit that connects to the Sealing Head was designed around a maximum allowable power
output. The primary current and voltage are constantly monitored and if the power output of the energy
unit exceeds the maximum allowable limit, this fault will occur. This fault can indicate possible problems
or failed components within the energy unit. Should this fault continue to occur, contact Lepel Service
Department.

5.3.10 Int. Board Fault

This is an Interface Board fault. The interface board inside the energy unit contains a microprocessor.
Should communications with the interface board fail, this fault will occur. This fault could indicate a
loose wire, connection or possible board problem. Contact Lepel Service Department.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 15

Section 5: Operation

Figure 3: Menu Structure

16 Lepel Corporation
 CS 200SS

Section 6: Maintenance

6.1 SCHEDULING
The Lepel CS 200SS Standard Sealing Head is designed for continuous service and minimum
maintenance requirements. The frequency of any maintenance program is a function of environment,
degree of equipment use, and product experience.

6.2 PERSONNEL
Qualified personnel must perform inspection and maintenance procedures only. Personnel must read and
be thoroughly familiar with all safety precautions discussed in this manual.

6.3 INSPECTION AND MAINTENANCE PROCEDURE

Note: Always follow approved lockout/tagout procedures before performing any service, inspection
or maintenance.

The following describes inspection procedures to be performed on a daily, weekly, and monthly basis.

6.3.1 Daily and Weekly Inspection

It is good practice to do a quick visual inspection of the unit, wiring and connections on a daily and/or
weekly basis. Report any apparent changes in performance to responsible personnel so that potential
problems can be investigated.

6.3.2 Monthly Inspection

Perform the following on a monthly basis:

1. Ensure all wiring connections are secure. Visually inspect for any wear on cabling.

2. Verify that none of the enclosure hardware has become loose.

3. Remove any build-up of debris that may occur around the air vents using a cloth or a vacuum. Use of
compressed air is not recommended.

4. Wipe the Sealing Head with a damp cloth to remove any dirt, prints or smudges.

Instruction Manual Document No. 0010-0257 (IM) (Rev -) 17

Section 6: Maintenance

6.4 SPARE PARTS

Recommended spare parts for this Sealing Head are:

1. Capacitor

2. Display Panel

Contact Lepel Corporation for further information on obtaining replacement parts.

18 Lepel Corporation