Pillartech
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Capsealing Equipment- Foiler Troubleshooting

Problem Possible Cause Solution
Undervolts Fault DC Bus Fuse open Open capsealer cabinet. Press Start, observe red LED on snubber board, located on the heat sink, on the back wall of the cabinet. If Red LED is lit, fuse is OK.
  Sealing Coil With power off, remove Amphenol power connector from sealing coil. Power up and press Start. If power meter begins to ramp up, coil is bad. Damage to the capsealer may occur if allowed to run without a coil for longer than 3 seconds.
  Inverter not firing Using a DC voltmeter, measure the voltage at TP13 on Main Control Board. With circuit breaker on, TP13 should read +1 VDC. Press Start, TP13 should rise to +8 VDC for approx. 1 second, then drop to +1 VDC, as Undervolts Fault lights. Measure voltage on TP14, repeat procedure. If either TP13 or TP14 fail this test, the inverter is not firing. See "Undervolts…Inverter not firing".
  Loose wire or connector With power off, pull on each wire to ensure it is tight. Push on each connector, to ensure it is seated properly.
Undervolts… Inverter not firing(failed step 3 above) Main Control Board With power off, (Ensure DC Bus is bled down) Disconnect wire # 7 from bridge rectifier. Disconnect quick disconnect terminal from Gate Drive Board. With a DC voltmeter, measure voltage on TP18, on Main Control Board. Power up. Read +15 VDC. Press Start. Voltage will drop to +8 VDC for one second then return to +15 VDC. Press Stop. Measure voltage on TP19, Repeat procedure.
 

Gate Drive Board


Note 1.

With power off, and wire #7 disconnected from the Bridge Rectifier, Reconnect terminal to Gate Drive Board. Carefully disconnect wire # 16 and #4, and #17 and #10 from IGBT Gate. Connect a DC voltmeter from #16(+) to #4(gnd). Turn on CB, measure –14 VDC. Press Start, voltage should rise to –1 VDC for 1 second then drop back to –14 VDC. Repeat step measuring wire # 17(+) and #10(-). Reconnect gate wires in the correct order.
  IGBT Failed See procedure for checking IGBT
  Power Interface Board Replace Power Interface Board.
Coolant Loss / Water Fault LED lit. Filter screen dirty On water pump, remove the large acorn nut and remove the filter screen. Clean filter screen with water or compressed air.
  Main Control Board Place a jumper between TBG-3 and TBG-4 (Wires #91 and #92) on Main Control Board. If fault does not clear, replace Main Control Board.Do not attempt to operate capsealer with this jumper in place. Damage to sealing coil may result.
  Recirculator water level too high or too low With pump off, check recirculator sight glass for proper level. The orange level indicator should float to approx. halfway up the sight glass. No water should be seen in sight glass.
  Recirculator pump Disconnect water hoses from sealing coil. Remove quick disconnect connectors from hoses. Direct hoses into a bucket and turn on recirculator. Flow rate should be at least 1 gallon per minute. Re-install connectors. Connect to sealing coil.
  Quick Disconnect Fittings Replace quick disconnect water fittings.
  Flow Switch Replace flow switch.
Output Current Fault Power Interface Board Replace Power Interface Board.
  Main Control Board Replace Main Control Board.
Overvolts Fault Loose connection at output transformer With power off, tighten all connections.
  Open connection in sealing coil Remove the box cover on top of the sealing coil. Check the condition of the wires that connect the power connector with the capacitor bank. If wires are scorched, replace the power connector.
  Output Leads With power off, disconnect power connector from sealing coil (leave other end of leads connected to the output transformer). Using an ohmmeter, check the resistance between the two conductors on the power connector. Should read 0 ohms. Rotate output leads near the power connector to check for intermittent connection.
Output meter ramps up past 100%. No control over output power…High Impedance LED may be lit (It is normal for High Impedance to be lit before Start button is pressed) See "Overvolts Fault
Low Impedance...Unable to achieve full power

Low input voltage.


(It is normal for Low Impedance to be lit before Start button is pressed)

With capsealer running at maximum output, measure input voltage. If voltage is below 205 VAC, contact Pillar Service Department.
  Buck-boost transformer and control transformer are not tapped properly

The control transformer has a 208 VAC tap and a 230 VAC tap. Ensure it is tapped properly for your input voltage.


If equipped with a buck-boost transformer, there will be a 208 VAC terminal and a 230 VAC terminal on the main terminal strip. Ensure you are using the correct terminal. See equipment user manual.

  Rectifier Using an ohmmeter, check the rectifier.
Low Impedance flashes as bottles pass under sealing coil (may have Trouble Sealing bottles) Output transformer not properly tapped With power off, Re-tap output transformer. One of the output leads should always be on H1, move the other wire to a lower tap (i.e. from H4 to H3)
  Low voltage problems

See "Low Impedance…


Unable to achieve full power" above

Press Start…Inverter On Lights, Output Control goes out, Can not achieve desired power level Sealing coil With power off, remove Amphenol power connector from the sealing coil. Power up and press Start. If output meter begins to ramp up, the coil is bad. Damage to the capsealer may occur if allowed to run without a coil for longer than 3 seconds.
  Power Interface Board Replace Power Interface Board.
  Main Control Board Replace Main Control Board.

High Temp Fault


(Thermal switch must be manually reset. It is located on the heat sink near the IGBT. To reset, press the red plunger in the center of the Thermal switch)

Insufficient cooling

  1. Check rotation of cooling fan located on the right side of the heat sink.

  2. Inspect heat sink for blockage of air flow. Blow out with compressed air if necessary.

  High ambient temperature Move unit to a cooler area or open the front panel and use an external fan to aid cooling.
  Main Control Board Place a jumper between TBF-8 and TBF-9 (wires #47 and #48) on Main Control Board. If fault does not reset, replace Main Control Board.Do not attempt to operate capsealer with this jumper in place. Damage to unit may occur.
  Thermal Switch Measure the heat sink temperature in the area of the thermal switch. If it is below 150oF and the thermal switch still trips, replace the thermal switch.
Power meter drifts down…may not be able to achieve full power…may ramp slowly Main Control Board Replace Main Control Board.
Both contactors engage…No output…No red fault lights lit Auto start contact not engaged (if used) Place a jumper between wires #93 and #77 on TB1. Re-start unit. See "Installation" section in equipment user manual.
  Sealing coil With power off, remove Amphenol power connector from the sealing coil. Power up and press Start. If output meter begins to ramp up, the coil is bad. Damage to the capsealer may occur if allowed to run without a coil for longer than 3 seconds.
  Main Control Board Replace Main Control Board.
  Power Interface Board Replace Power Interface Board.
Unit runs but intermittently shuts down…No red fault LEDs lit. Water flow problems. See "Coolant Loss / Water Fault LED lit" above.

 

Note 1. Older Gate Drive Boards will give readings of –7VDC to +3 VDC. These boards should be sent to Pillar to be updated.