Support

243 Support Entries

Question

How are the blank cutting tolerances?

Resolution

Please check the PDF Blank Calculations and Tolerances

Important things to know:

• One canbody cycle = 0 – 360 °
• “Mclk Sync Deg” stands for Machine clock synchronization (in °). You can shift the clock/cycle signal (0-360 °) in order to get a proper synchronization of the graph to the measured canbody.
• A smaller value will shift the graph to the left,
• a bigger value to the right.

1. Problem:

The graph is not showing any values / no picture at all.

Possible Causes & Resolutions:

• The first parameter “Mclk Sync Degree” has a “dead area”, where the tool sensor detected the gap between the two cans, rather than the cans. As a result, there might be no graph showing. No graph showing means the system is not detecting that a can was welded.
➔ If no graph is shown, try to enter values in large steps. You should now see a graph but might have to adjust the measured area. Please see second problem for the resolution.

2. Problem:

The graph of the G-Sensor does not show a steady graph but shows greater fluctuations (= can gap).

Possible Causes & Resolutions:

• The G-Sensor is not correctly installed and measures outside the canbody cycle.
➔ In order to remove the greater fluctuations out of the graph-frame, increase the “Mclk Sync Degree” value to shift the graph to the right, and decrease the value to shift the graph to the left.
Example: Your graph looks like the left picture below. You will have to decrease your value by about 40° in order to receive a graph like on the right.E.g. you have a value of 180° and have to decrease by 40° = enter 140° OR you have a value of 20° and have to decrease by 40° = enter 340° (canbody cycle goes from 0-360°)

Problem:

iPad does not connect to the machine. Screen remains gray and shows no values.

Possible Causes & Resolutions:

• Connection via Wi-Fi
• In the settings, check whether the iPad has connected to the correct Can Man Wi-Fi
• If no Can Man Wi-Fi is visible, check router/wireless access point.
➔ Restart router/wireless access point. If still no Can Man Wi-Fi is visible, the router/wireless access point has lost the settings or is broken. Contact Can Man via by opening a new ticket.
• Connection via Cable
• Check all plug connections of the network cable between IPC and iPad
• Check iPad adapter power supply. The adapter must always be powered, otherwise the connection will not work.

Battery of IPC is empty when:

• System Date and Time (Error Log) not correctly displayed and getting lost when powering off the IPC.

To Do:

Reason for error message:

• The Pacemaker™ HF has detected a missing phase.

Possible causes:

• Supply voltage mains (all three phases) 400V
• Check the small fuses on the bottom of Pacemaker HF
• Check complete wiring, Are all clamps tightened?
• Measuring voltage at the input terminals on the main board (see attached picture)
• IC “OC14” or phase measurement is defective. Replace the IC, Type HCPL3700

For a Pacemaker-repair we calculate / estimate a “cycle-time” of 2 weeks, including final testing and packing. If a faster service is required, extra charges occur. In case the number of incoming repair jobs is unusual high, it might take more than 2 weeks.

Note the adjustment of the clearance of the roller after the BIG8 monobloc cutting heads is ELEMENTARY to prevent bow cuts!

Check if the roller is not “tilted” (and thus one-sided “in the air”), refer also to manual of your slitter how to adjust the roller.

Possible causes:

• blank cutting (especially development) not within tolerance
• inconstant overlap – Z-bar worn (—> for “overlap variation“ see also here )
• wire tension not correct
• calibration crown inconstant (for example due to worn bearing)
• wrong adjustment of „overtravel“ of final pusher system (see instruction manual of your welder)
• „backlash“ in final pusher system due to worn bearing or linear guides
• copper wire profile not correct

ATTENTION:
If you have a ceramic Z-bar e.g. X7 welder, please not that the ceramic Z-bar is very fragile.
In case you have to exchange or to replace the Z-bar, never use a hammer or apply excessive force!

Find here the status LED’s of the Beckhoff PC
and how to access the PC in case of a trouble shooting.

Possible causes:

1. The serial reduce (Powerfoil) is active
2. Timing from the welding pressure to vacuum “ON” is too short
3. Wrong setting of t1 & t2
4. Mechanical setting might need to be adjusted
(only for unwelded sections at the beginning)

What does this error message mean?
CCD = concurrent connected data variables.

The amount of active CCD is limited. Opening the HMI is using some of the available CCD.
Closing the HMI is releasing the CCD again.
When you repeatedly open and close the browser, the CCD can still be in use and getting into the limitation.
(There is a delay for releasing the CCD when closing the connection).
„If a client wants to subscribe to new data variables while no more CCDs are available, a message “CCD exceeded!” will appear and there will be no communication with these data variables.“
„If a client disconnects from the visu (e.g. browser gets closed), it will take some time until the browser session expires and the CCDs from this client become available once again (session timeout of the scada server: 2 min.).

How to solve a CCD exceeded?
Close alle open browser connection and wait for >2 min.
Now you should be able to open the HMI without error message.

How to prevent a CCD exceeded?
Don’t open the HMI in several browser simultaneously.
Don’t repeatedly open and close the HMI in short time.
Don’t repeatedly press reload the HMI in short time.

Possible cause:

Diodes between IGBT’s are damaged

Measure /  exchange diodes

Problem:
The decrement counter shows the number of cans between the welding station and first light barrier of the eject station. If the value is wrong, the ejection of cans is out of sync with the faulty products.

Resolution:

• The reason for a wrong decrement counter can be a reset during production.
Attention(!): Reset the decrement counter only if the production is stopped and no cans are between the welding station and eject station, NEVER during production! This is important to avoid that bad cans go to the downline.

Problem:
The decrement counter is not stable, which leads to continuously smaller values during full production.

Possible Causes & Resolutions:

• Tooling sensor signal is not stable. The tooling sensor might not detect all cans properly due to the distance between the cans and sensor.
➔ Please check the distance of the sensor to the can, it should be as close as possible without it touching the can.
• Cycle signal of machine is not stable.
➔ Check the cycle signal: If the machine signal comes from a sensor, check sensor settings or replace sensor.

Possible cause/checklist:

1. Slitter:
• Angular errors below 0.05 mm per 100 mm
• Burrs below 20% of tin plate thickness !
2. Air pressure:
• Welding pressure 2.6 (aerosol) to max. 2.8 bar (beverage, food), equal to 45 – 48 daN.
• Wire tension cylinder profiling unit 1.6 bar
• Wire chopper 2.4 bar
• To move tooling (which air regulator find on touch screen: “Air”, page 5/8) pressure should be 3.0 bar.
• To lift up guidance channel (page 5/8) pressure should be 1.0 bar.
3. Lower welding arm/Z-bar:
• Take off the upper and lower screw off one by one, check the insulation washers, if they are squeezed too much, change each them!
• Check the insulation of the complete Z-bar:  > 10 MegaOhm
• Measure the deflection of the X-Plane at a welding pressure of 45 daN (2.6 bar): Between 0.1 – 0.15 mm
4. Check all the Z-bar grooves:
• Especially the last 100 mm, incl. front Z-bar tip (called nosepiece), maybe they are worn out.
• Sometimes some tin deposits can slow down or disturb the movement of the tin plates -> can gap unsconstant, cold begin/end.
5. Welding roller grooves:
• They have to be clean and the ground of each groove must be straight!
• If you are not sure, re-groove them
6. Copper wire width:
• Check this according manual. Guideline: Width of copper wire always between 0.03 – 0.07 mm below profile width of welding rollers
7. Reset the whole tooling according manual (if not yet available in your manual, ask Can Man)
• Reset the calibration crown /tooling: Check the play of the top diabolo roller bearings.
8. Lower welding roller height:
• Set it around 0.3 mm over the Z-bar center. How to do:
• Weld cans, and check the roundness:
• Apple shape: Tooling too high, or welding roller too low or check this FAQ here
• Roof shape: Tooling too low, or welding roller too high
• The height of the tooling should be between – 0.2 and + 0.2 mm, shown on the handle/shaft underneath the tooling. If needed, move the height of welding roller again, till the roundness of the can is sufficient.
9. Reset the upper pendulum rollerhead:
• Angle: Normally not necessary, as long as nobody touched/dis-adjusted red marked screws on the support).
• Horizontal axle: Make sure that the height of the pendulum axle is parallel to the welding roller axle. Use for this setting a precise level, and level the shaft of the pendulum rollerhead according the level of the welder, or do it according the manual, using the delivered gauge set.
10. Position of exit conveyor:
• Use the delivered stainless steel gauge, put it into the tooling, and let both belts (of the OHC) touch that gauge slightly.
• Make sure the OHC is parallel to its basic plate on the lift
11. Position of diabolo center between 1–3 mm before lower weld roll center.
• Conical overlap:
• Too much overlap in the beginning: Move tooling foward, 0.5 mm/move
• Too much overlap in the end: Move the tooling backwards, 0.5 mm/move
12. Can gap tolerance shall be within 0.5 mm:
• Can gap on aerosol: 2.0 – 3.0 mm
• Can gap on beverage/food: 1.5 . 2.5 mm
• Belt for pendulum rollerhead should be tensioned tight.
• Belt for profiling unit must be tight, before and after the profiling unit
• The clearance between wire chopper transport rings must be 50 – 60% of the profiled copper wire thickness
Example: Copper wire thickness 0.60 mm, clearance adjustment 0.30 mm
13. Overlap:
• 0.5 – 0.60, not less, not more
• Check the overlap only by an internal diameter gauge, with a dial indicator to read result. Diameter tolerance should not be higher 0.1 mm.
14. Check the tin flow after the upper, and after the lower welding roller on the copper wire.
• Do not accept anything but the center
15. Check the overtravel of the can body:
• Move the pusher finger to the very front, and measure the distance from the pusher plate, until the center of the lower welding roller.
• Now deduct this measure from your cutted tin plate height and you know how many mm the tin plate gets pushed over the center of the lower welding roller.
Attention: If you have spatters on the beginning of the can, which show backwards, move the transport carriage backwards. Do that over the can height setting on the touch screen.
16. Rollforming:
• The rollformed body must be round, and both edges shall be parallel to each other
• Rollforming overlap: E.g. ø 65, min. 5 mm, max. 8 mm
17. Check following after all these settings:
• Weld 10 cans and do not cut the copper wire:
• Check the wire gaps (gap between tin flows) on the copper wire. Tolerance should be < 0.5 mm
• Measure each wire elongation, and compare them. Tolerance should be < 0.5 mm
• Check condition of synthetic roller. Ensure that application surface is smooth and does not show any defects > replace if required.
• Measure velocity of overhead conveyor at welder exit for reference purposes. Set speed of outside lacquering unit equal to conveyor or alternatively, set it slightly higher (2–3% above effective conveyor speed)
> verify speed setting by measuring exact velocity, picking up speed of application surface at synthetic roller.
• Apply slightly more lacquer on outer side seam. Please follow therefor point 7.2 (Adjustment of the lacquer quantity) in the provided instruction manual for the ORC.
• As a last precaution, check the viscosity of your lacquer by using the DIN 4 cup supplied. Recommended viscosity: 20–25 seconds. Depending on type of lacquer used, add corresponding thinner / water in order to achieve required viscosity.

IMPORTANT: The inverter parameter setting must be exactly same like before (original setting). Otherwise motor will burn!

Reference for thickness of the welding seam is related to thickness of material (this value is variable, depending on the overlap of the welding seam, material as hardness and tin coating, welding pressure, welding current and welding frequency).

T = S x 1.75
T = thickness of the welding seam
S = thickness of tin plate

Example:

T = 0.15 x1.75 = 0.2625 mm

Necking tool tolerance

D = S+W+L+P+E (mm)
D = difference between inside/outside diameter of necking tool
S = thickness of tin plate
W = thickness of welding seam measured by micrometer (we should measure beginning, middle and end of the welding seam)
L = thickness of outside lacquer stripe 0,02 mm
P = thickness of inside powder stripe 0,07 mm
E = extra space (0.05 mm)

Example:

D = 0.15 + 0.26 + 0,02 + 0,07 + 0.05 = 0.55 mm
S = 0.15 mm / W = 0.26 mm / L = 0,02 mm / P = 0,07 mm / E = 0.05 mm

Check these two PDF documents:

Use this Excel-Form for your calculation.

• H – grain means rolling direction parallel to the welded seam
• C – grain means rolling direction crosswise to the welded seam

• Empty the water tank. On 2-circuit cooling unit only cold water tank has to be emptied.
• Blow off one by one each cooling circuit in the welder. This allows to empty each circuit separately. If your welder has a 2-circuit cooling system only the circuit for the lower and upper weld roll has to be emptied.
• Change the filter cartridge and clean the filter housing inside.
• Fill the tank with water only, open main valve Y14, and run the system for at least one hour to flush rests of old emulsion out.
• Empty the water tank again and clean again if necessary.
• Fill the water tank with water (or distilled water if requested), and mix the PowerRoll™ coolant H1 in with 8 percent.

We recommend following maintenance procedures:

• Change the filter cartridge monthly.
• Change the cooling emulsion yearly. Use the PowerRoll™ cooling system cleaner at any time you change the emulsion.
• Use the PowerRoll™ cooling system decalcer after around 5 years.

Order numbers:

• PowerRoll™ coolant H1 (food grade), 7 Liter, 011494
• PowerRoll™ cooling system cleaner H1 (food grade), 10 Liter, 011495
• PowerRoll™ cooling system decalcer, 25 kg, 011496
• Filter cartridge 50 µm, 002446

Safety data sheets see below:

PowerROLL Coolant System Decalcer

Possible cause:

• insufficient cooling
• clean cooling circuit
• change cooling additive / lubricant in the chiller
• clean or change main- and micro-filter in cooling system (see pictures below)

• Check insulation
• feel hot spots in the entire secondary circuit by hand or use IR camera if available.
• Check Z-guide for broken parts (nosepiece or main Z – bar or, depending on welder type, intermediate Z-bar)

Possible cause:

• LED on the converter does not light up!
• Lenze frequency converter defect
• If LED is red, check error code with the keypad.

NOTE:
In case you have to replace the converter, make sure you load the default parameter setting. All the latest models, do have the parameter setting in the electrical scheme – if you do not have the parameter, contact Can Man by filling out a ticket in the support section on our website.

Possible cause:
The upper pendulum roller might be not leveled properly. When regrooving the upper disc for example 0.50 mm in diameter, the height of the pendulum rollerhead must be reduced 0.25 mm. This can be done by the M10 screw on the back side.

NOTE: The description manual is based on a CM X1 welder, but it works very similar for our other welders.

ATTENTION: Do not touch the red marked screws!

Your cooling system has to be checked and / or one or more circuits need to be cleaned.

Explanation:
If the temperature difference exceeds a certain value, mechanical mis-alignments may occur which can affect the welding geometry. Obviously it is not the same when a welder is cold (start of production) and hot (after up to1h of production).

NOTE: With Can Man TempGUARD™ system, this can not happen anymore.

1. Measure the overlap by reducing the welding current until the sheet edges can be broken apart to check, where the overlap is incorrect. NOTE: Machines with a PACEMAKER™ do have a „overlap check“ in the menu!
2. Check the blank cutting.
3. Check the condition to the nose piece (even maybe the Z-bar).
4. Check the „clearance“ of the calibration crown roller (also called hour glass or diabolo rollers), with special attention to the upper ones.
5. Check the position of the exit conveyor (weld a can without the conveyor and see the difference).
6. Check whether the idler wheel in front of the lower welding roll is in correct position, or whether the circlip is missing (Xplane only)!

If you still couldn’t resolve the problem, read more here.

1. Remove welding pressure and check if deviation of upper (outer) rollerhead (in most machines the pendulum rollerhead) is working properly (free of any mechanical friction or resistance)!
2. Follow 1. and check „copper belts“ (the flexible power conductors between the rollerhead and the upper bus bar) and that they are not give mechanical resistance (counterforce) to the welding pressure.
3. Following 1. and make sure that the „lift“ of the upper rollhead is not disabling the welding pressure to be fully obtained to the lower welding roll. This can happen if the both welding roller diam. are smaller than allowed.
4. Finally check, ideally with a „tension spring balance“, the actual welding force (usually it should be within 40–45 daN)
1. Change welding frequency (use Can Man PACEMAKER™)
2. Change to another type of sheet and / or tin coating and monitor the difference.
3. Make a „screw check“, especially of the secondary power circuit and the z-bar assembly.
4. Use another overlap
5. Check if any of the welding roller bearing have to much clearance (change them if so).
6. Check the condition of the pendulum rollerhead.
7. Check proper function of welding pressure assembly (see also „problems with welding pressure“).
8. Check welding geometry in general.

Possible cause:

1. It might be that you‘ve changed the type of tinplate (hardness or tinlayer).
2. It might be that you have changed the welding frequency.
3. If it appears a problem and you need help follow:

According to the drawing below.

The gap between the cans is not constant (see picture below).

See also following FAQ-article Why can’t I keep the distance from can to can constant?

1. Check blanc cutting tolerances  and in particular dimension h
2. Check clearance (wear) of final canbody pushing system.
4. Check blanc cutting tolerances and in particular dimension A on a series of sheets (3-7 sheets depending how many knifes are cutting dim. A on your slitter).
5. Check the speed of the exit conveyor belt(s), which need(s) to be constant and in any case 2 – 5% faster than the actual welding speed.
1. Check calibration crown adjustment, it is probably to loose.
2. If 1. is checked with mandrel and you still have the same effect follow What to do when the overlap is too big in the beginning and / or too big in the end of each canbody.

Possible causes:

• Check the blanc cutting tolerances and blank squareness.
• Adjust the rollformer (roller shaft clearance and spring pressure) according to the manual.
• Control if there is a high difference in the tin plate hardness, by rollforming 10 bodies without welding. Put them on the floor in line and compare the difference in the rollforming overlap.
• Check if the destacking process is going well. Make sure the tin plate is guided tight, and the separating air is positioned well.
• Control the timing of the tin plate transport in between two transport fingers.
• Make sure that the guidance channel is properly adjusted. The intersection to the precalibration of the calibration crown is most important.
• Check the position of each (inside and outside!) transport finger compared to rollformed canbody.
• Check the offset of each finger pair itself. Move the canbody slowly forward (X1 and X6 by slow mode function) and observe eventual shaking of the canbody until the welding point.
• If a third finger exists: The third finger must be 0.5 mm behind the upper main pusher fingers!
• Reset the calibration crown completely. Make sure that each precalibration roller is turning easily! If needed lubricate their shafts slightly and clean the roller afterwards. Make sure that these rollers are as close as possible to each other!
• Measure the speed of the flat belt in the calibration crown:
The speed must be absolutely identical with the copper wire speed!
• Measure the overtravel: Short can heights shall have 1 mm overtravel.
• The center of the diabolo roller (equal to the center of calibration crown) shall be 1–2 mm before the welding center.

 X1 950 mm X8 1020 mm CM15 1100 mm CM16 950 mm CM17 1050 mm CM20 1250 mm CM21 WIMA 1000 mm

Please note that those are minimum heights!

For more detailed dimensions, see products page > technical data > Layouts

Check for proper adjustment and alignment of separator-notches, rest bars and sucker bar.

• The fan unit can be removed. Check whether the fan is correctly mounted (screwed).
• The fans can also be removed and cleaned if dirty.
• Replace the defective fan unit!

NOTE: Make sure that the wire is not touching anywhere. Only a perfectly set and maintained canbody welder, can assure perfect welding! A weld monitor is a pure “measuring instrument”.

Check this specific wire crossing (red arrow). The wire might touch each other here!

Switch OFF the QM eject function and record the curve.

Curve not stable!

Check the connection from the voltage pickup to the Qualimaker board.

1. Put an isolation between the roll and the voltage pickup.
2. The lower voltage pickup should be isolated to the Z-bar.
3. Measure from the lower voltage pickup (1) to the upper contact (2) (Z-bar connection). This should be 0 Ohm! (see first picture beside)
4.  Measure from the lower voltage pickup to the Qualimaker clamp 125/126, one off them should be 0 Ohm! (see second picture beside)
5. Measure from the upper voltage pickup to the Qualimaker clamp 125/126, one off them should be 0 Ohm!
6. Measure the voltage on Qualimaker clamp 125 to 126 during welding
• the voltage should be between 0.5 and 2.5 VAC

Cause may be a short. Make sure that the bracket of the IR-sensor is complete isolated. No bolts etc. should touch the rocker arm or other parts.

Possible cause:

• Check if the voltage pick – up “tongues” are worn.
• Check if there’s enough “contact pressure” of those tongues
• If they are bent; change them, do not attempt to bend them yourself, they might break!

Possible cause:

• Defective print.

Corrective:

• Replace the small print for eject station.

Possible cause:

• The power percentage is too high! If the power percentage rises up to 96%, the LED is flashing. In this case the pacemaker does not have enough spare power to regulate the current properly.

Corrective:

• To solve the problem, reduce current/frequency value or use a highertransformer step.

Cause:

The actual value of the weld power limiter increases with the heating of the machine.

Corretive:

Readjust the weld power limiter, to a higher value. Observe the “Max” value from a “cold “ start to a “warm up” machine during production. See also note below.

NOTE:

Power limit to activate the weld guard (stitch welding). Normally 5 – 10 % more than the actual “Max” value during production.
0 = Weld Power Limiter Off !

Possible cause:

• Short circuit in the welding transformer!

DO NOT ATTEMPT TO SWITCH “ON” THE CURRENT ANYMORE!
Further attempts to switch on the current, can destroy or damage the semiconductors (IGBT) in the Pacemaker!

An overvoltage suppressor (or surge suppressor) is an appliance designed to protect electrical devices from voltage spikes. A surge suppressor attempts to regulate the voltage supplied to an electric device by either blocking or by shorting to ground voltages above a safe threshold.

These surge suppressors are built in to the latest Pacemaker models (from 2009).

Check, if one or more plugs of the surge suppressors are red/defect. Replace the red plugs.

CM article No. 008052

Important requirements:

1. t2 must be always higher than t1 (t2 > t1).
2. t2 and t1 must be set lower than 1 cycle time of the machine. For example, if the machine is running with 300 cans/min the cycle time is 200ms. Therefore, t2 and t1 must be set lower than 200ms.
3. To do an overlap check set  “overlap check” to “ON”. The reduced current will be set automatically to 0A. In the same window you have an additional value. If you set this for example to 10ms you have more unwelded area at the beginning and end of can.
NOTE: If you use “overlap check” function is not necessary to switch “Ired” to “ON”.

Possible problems, if the overlap function does not work!

• If you can’t see the value t2 and t1, maybe the pacemaker is running with “Old” mode and not with “CMX” mode. Change in the setup “CT” from “Old” to “CMX”.
• No input signal on input 4 (terminal 7 and 8 on pacemaker board). If machine is running, LED behind input 4 (clamp 7 and 8) must flashing. This is the cycle signal to start the timer t2 and t1 for the overlap check.

Possible cause:

• Check your welder according checklist Conical overlap / micro leaks
• If your Pacemaker is programed to weld with sine wave (check the IBS), we can change to triangle wave form.

The Pacemaker™ static welding inverter has a RAM battery for data retention and clock-buffering at power interruption/disconnection. The battery has a limited life span (about 5 years) that decreases especially without power supply (controller off). To prevent loss of data, the battery must be replaced early enough.

The parts can be ordered in our webshop or with prepared form.

Possible Cause:

1. Check air supply for the cylinder.
2. Second light barrier is always ON.
LED on light barrier must be ON without can, OFF if a can is detected.
3. Adjustment of the light barrier distance to eject cylinder might be wrong.

4. Wrong adjustment of the transport belt speed.

Possible cause:

Using a handpanel:
When you start up your Pacemaker, the software version will be displayed during the boot process.

Alternatively the information will we displayed, when you press the key “down” several times until you get to “Info Version”: e.g. 5.27

Using a CM16 welder you will also find the info by pressing the key “down”, since the display is the same as the handpanel of a PM.

Using a X1 welder:

Tip on the *eye” icon and the Pacemaker software version is displayed on the bottom line.

Using X8 welder:

Tip on the “eye” icon and then on a second “eye” icon to get to software version info on the bottom line – check also your manual book 1 – chapter 4.6. how to find the info.

Possible cause:

• Check if the wire speed is stable and not too slow? Sometimes two cans might be welded together (no gap)!
• Check if the speed of the exit conveyor is fast enough? The gap between the cans must be minimum of 10mm.
• Clean the first light barrier and the reflector and check the adjustment!
1. Switch off the main switch Q1 of the machine.
2. Wait around 10min before you do anything on the wiring of the pacemaker! The capacitors need that time to discharge!!!
3. Disconnect both welding cables from Pacemaker.
4. Measure the resistant of both cable to earth. If the value is very low maybe the transformer primary side have short circuit to earth or the cables are damaged and make some contact to earth. If it looks ok (endless or very high resistant) go to point 5.
5. Take the welding copper wire completely out of welder.
6. Control that pendulum roller head is lift up. Put a carton or another insulating material between both welding rollers to make sure that you don’t have any contact between the rollers.
7. Connect an external cable 230VAC (phase and neutral) to the welding cables, which you have removed on pacemaker before. Use for this external supply a 10A fuse breaker to protect the supply in case of a short circuit of welding transformer. (Take a look to picture on point 3)
8. Before you switch on the external supply check again:
– Wire removed?
– Pendelum rollerhead lift up and isolation between welding rollers?
9. Now switch on the external supply. If the 10A fuse breaker does not trip it is a good sign and it doesn’t look like short circuit of welding transformer.
10. To control the output of welding transformer you can measure the voltage between the welding rolls (VAC). The measured voltage is depending on the type of welding transformer. If you change the transformer step this value has also to change. Check the output voltage of each step. Don’t worry if you measure only around 5VAC, the output voltage of welding transformer is a low voltage.

Before you change the transformer step switch off first the external supply!!!

Possible cause:

• the welding roll might be defect
• change welding roll
• in case you use a mercury based welding roll
• the pendulum roll might be defect
• change the pendulum roll
• in case you use a mercury based pendulum roll
• the transformer step switch might be defect
• change transformer step switch

NOTE: The reason for the low current is due to an open circuit. The wire might be also hot in this case. If you have in general a high power percentage you might reduce the frequency.

Scroll down in the display menu until you reach the temperature display. Observe, if after crossing the switching threshold, the temperature doesn’t change, that the solenoid valve is blocked (when the 2nd thresholds are reached the message “over- or undertemperature” will be displayed).

NOTE: The error message “Ths too low (Ths = Temperature Heatsink)” might be an indication for a contaminated valve.

Possible cause:

• Welding transformer has short circuit on primary side (see How to find out that the welding transformer is damaged / broken?)
• The cable or isolation to the welding transformer is damaged
• IGBT broken
• Exchange the contacts (CM article 005640) of the main contactor, or the complete main contactor (CM article 003217).
(NOTE: This is only applicable, if the error message shows up, when you start up the Pacemaker).

The Pacemaker has the following options to connect the output of the weld power limiter to other systems/controls (i.e. can rejection control):

1. E-Relay
E-Relay of Pacemaker does stop the welder if weld power limiter is active. To connect, use the clamp No. 45, 46 and 47 (potential free relay contact 47=>com, 46=>nc, 45=>no).
To use this function, the parameter “Wld fault” in the Pacemaker settings has to be set to “E-Relay”. If weld power limiter is activated, the E-relay do switch on, welder stop and must be reset on the Pacemaker display before the welder can be restartet. Of course the operator has to check the last welded cans to make sure that no unwelded cans go to the downline.
2. +Tol output (Clamp 35/36, 35=>0V, 36=>24Vdc)
This output is switching on if the weld power limiter is active and can be used also to activate an ejector or other function. The next can will be welded normally and +Tol output will switch off automatically. If you want to use that output, you can change the parameter “Wld fault” to “nothing”. In this case, the E-relay will not be activated and the welder can run continuously without to stop if the weld power limiter detect a can. Of course you need an additional logic for the eject timing and eject the right can.
3. +CR output (Clamp 39/40, 39=>0V, 40=>24Vdc)
This output will be activated if the weld power limiter is active according to the parameter “WLD fault”. You can choose different settings like “CR39/40”, “CR 50ms”…
Example: CR 50ms => Pulse of 50ms on CR output if weld power limiter detect a bad can.
4. Can Man eject unit
With this option it is possible to eject cans and also to eject the first and last can of a series. Please contact Can Man for an offer.Attention!!! +Tol and +CR output is supplied by the internal 24Vdc of the Pacemaker electronic board. This output is not potential free!!! Use a small 24Vdc relay to connect the signal with other systems/controls.The settings of beginning and end of can (T1/T2 or IT/ET) must be set correctly, also if you don’t use the IRED function. With this timing, the weld power do switch on the current for the next can after a stop in case of contamination (overlacquering).Code to enter the system setup: down, right, left, left, up, left, right, right

Possible cause:

• Check if the voltage pick – up “tongues” are worn.
• Check if there’s enough the “contact pressure” of those tongues or if they are bent. If they are bent; change them, do not attempt to bend them yourself, they might break!

• Short circuit (see picture/graph beside)
e.g. lower tongue has contact with power window!

• check wire – usually after a short circuit the wire is damaged!

• Short circuit (see picture/graph beside)
• the wire might be damaged/broken within the Z-rail.

Potential remedy

• Check the „over voltage limit“ in the basic-setup.
• Check the “voltage limit” in the basic setup.
• Check the inputvoltage (400Vac).
• Is the wiring between C-bar (voltage measuring) and HF controller correct?
• Check the voltage signal over the C-bar. The voltage peaks should not be higher than the “over voltage limit”. To measure you need a scope meter and a differential probe or a scope with isolation to ground. See the pictures of tools, where to connect and how the signal looks if everything is fine.
• Check if the IC OC17 (Type 6N137) is faulty.
• Try to start the generator. If not successful, request support.

Possible reason choke coil defective

• Separate the choke coil from the original circuit and measure with an inductor → if the inductance is reduced a lot it mean is defective
• original value = 320 microHenry
• Check function of the valve
• Check water circulation to the pacemaker
• Check the water pressure
• Check function and the contamination of the ventilators.
• If necessary clean or change them.

If the voltage value drops below 350 V the error message “Phase voltage error” shows up.

Check the main supply: L1 / L2 / L3.