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Possible causes:

• Check the blank 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.

Possible cause:

This can only happen on higher can heights. The canbody to be welded, is extending with its back into the rollforming area, while the next tin plate is coming out of rollformer and touches the backside of the tin plate. The sharp edge of the rollforming plate scratches paint away. This paint is being welded thereafter in the seam.

 Correction:

1. Reduce the Linmot cycle time, but not less than 500 ms (access with password customer 1). The can is now pushed faster into the welding area. This might already solve the problem.
2. Adjust the timing of the feeder delay and compare to Linmot pusher (see manual book 1, chapter 4.5.3.)
3. Increase rollformer speed if necessary, to reduce the rollforming process, because of delayed feeder.
4. Try step 2 and 3 til ok.

Problem:

Error message: “Jam canbody transport”

Possible Causes & Resolutions:

• Calibration crown: Possibly is adjusted too close (too much overlap). This can cause a high resistance. Readjust according manual.
• Slider condition: Switch of machine and move the slider by hand. It must move smoothly. Since the slider of the linear motor contains strong magnets, remove dust or small metallic particles from the slider (see picture beside). To do this, remove the front cover.
• Wrong adjustment of curve time: Curve time means the duration for one complete move of linear motor. It must be shorter then one machine cycle! Example: Production speed => 120cpm => Machine cycle 500ms => curve time must be lower then 500ms.
• Enable signal of plc lost (Error message Linmot controller “User Err:Motion Cmd in Wrong St.“): Check wiring between PLC module and Linmot controller. Check PLC module. Clean the contact surfaces between the PLC modules with contact spray.

Additionally checkpoints for X8 with air cylinder downstacker

• Function of the valve Y1 for downstacker: Watch the LED on the valve for consitent timing / on – off switching. If inconsitent, please check output on PLC (Vipa output A4.6, Beckhoff output BA117 1/9), wiring and plug to valve or replace solenoid or entire valve.
• Cylinder condition: Possibly is worn, therefore check for are air leaks in both positions and to much backlash between piston rod and cylinder body. Removing air hoses (or air pressure) and move the piston in and out (up and down) manually.

NOTE: If you did remove the bracing, reassemble correctly. Check the insulation and tighten the self-locking nut only slightly, that the connection can adjust itself.

• Check first whether the conveyor / elevator unit is blocked somewhere!
• Check the 24 VDC fuse according electrical diagram. Make sure that the correct size will be used!
• Check the setting of the respective sensor (according electrical diagram), which allows the conveyor to move if the sensor is active / free!
• Take the 24 VDC motor out, and check whether the motor is defective or not! Make sure that the conveyor is not moving downwards as soon as the mechanical connection between motor and elevator unit has been released!