Support

24 Support Entries

Possible cause:

Diodes between IGBT’s are damaged

Measure /  exchange diodes

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.

Check

– Check the cooling-water-inlet.
– Check the “Ths” and “Tamb” on the display.
– Check the small fans of the Pacemaker

 

NOTE:
The error “Ths too low” means temperature heat sink (copperplate) too low. If the copper plate is too cold. It can damage the unit, if some condensation water flows to the electronic power parts.

 

Check if the valve closes correctly and clean the valve.

NOTE:
If you reassemble the valve, make sure you do it the right way (see picture)

 

Check the correct water flow direction.

Download PDF here

NOTE: The pictures showing a regular Pacemaker and not a Pacemaker HF as used in the PowerCure, but the issue is the same!

Potential remedy

  • Check the „over voltage limit“ in the basic-setup.
    Password for overvoltage (max. 900V) = “MENU-DOWN-ENTER-UP-DOWN-UP”
  • Check the “voltage limit” in the basic setup.
    Password for “voltage limit” (max. 565V) = “UP-DOWN-ENTER-UP-MENU-DOWN”
  • 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.
  • 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

When you start up your PowerCure equipment, the software version (here called generator data) will be displayed during the boot process.

Alternatively the information will we displayed, when press “MENU” and then press the key “down” several times until you get to “Preheater Info”:

There are two Software versions displayed:
e.g. – S/V 2.65 and EPLD V63

 

Software Upgrade:

The software for the Pacemaker HF is memorized on a small processor board. For an update with new software, you need to change this board.
NOTE:

Before you start to change the board write down the voltage value you were using for your application.

 

Switch off the main switch of PowerCURE™

 

WARNING:
Wait 5 minutes, before you remove the cover. Capacitors with high voltage inside!

 

Remove the processor board carefully by hand. Do not use any tools for that.

 

Install the new processor board.

 

NOTE:
Be careful and make sure that you mount the new processor board correctly and that pins match the socket!! Watch from the side.

 

NOTE:
When you first start up, use a low voltage of approx. 80 V.
We hope the upgrade work was successful. Thank for your support!

Requirement:

  • The cooling energy should be 3 kW or more.
  • Cooling water temperature not below 20°C, due to the condensation at the coil.
  • The water pump should be able to generate a min. of 4 bar pressure at the inlet of the PowerCURE™ with a pump capacity of min. 10l/min.

Customer options:

  1. You buy your cooling system – you are responsible for the required technical data.
  2. You’re planning to buy a larger cooling unit for the PowerCURE™ and the welder, you must add the data of both systems requirement together. Ask the original welder manufacturer for the cooling data and remember; if the cooling water for the welder is required to be below 20° C, you must split the system in two circuits with independently adjustable temperatures.
  3. You order the cooling unit at CanMan.
  4. You buy a CanMan welding machine with seam protection and a PowerCURE™. In this case we will deliver a combined cooling unit, which cools the welding and the PowerCURE™ unit.

Correctives 1 – Too much heat during the first part of the curing process:

1.1.  The tin flow has to to be only as wide as the width of the powder and / or lacquer stripe and not more (usually around 15 mm for food and aerosol cans)!
- This width covers also lateral shifting can bodies during daily production!
- The internal powder must have a low melting point, starting from about 180°C!
- Most commercially available and good powder coats are fulfilling this demand For further information for recommended powders, please contact Can Man.

1.2.  The conveyor speed in the oven is too high, therefore the curing time too short!

– Distances between the cans of more than 1/2 canbody height is a reduction in curing time of 25% (or from 5 sec. to only about 3,8 sec.!)

1.3.  The adjustment of the coil to the can bodies is wrong.

1.4.  The curing length is too short (before order a longer curing system, please follow first the Correctives 2 and 3!)

Corrective 2 – The wet lacquer application is not constant, too thick or too thin!

2.1.  Especially for induction curing system, with shorter curing time, a constant film thickness is required!

- Please note that a constant and a “as thin as possible” lacquer application is essential not only onthe curing effect, but it also reduces the lacquer cost!

2.2.  The can body must be round – within standard tolerance -, overlap begin and end must be equal!

2.3.  Depending on the configuration, rubber roller or steel rollers must be used!

- For further information and / or support contact Can Man.

2.4.  The speed of the application roller is wrong, compared to the passing can bodies!

- Generally can be said, that a too high application roll speed leads to worse results than a too slow one.

- Depending on steel or rubber rollers different speed than can body speed might be used, but must be controlled and monitored.

2.5.  The material and / or the form of the rubber/steel roller profile is wrong!

- For the use of a steel roll (longer lifetime) we urgently recommend to have a “supporting conveyor “under” can body (available at Can Man)

Corrective 3 – Wrong wet lacquer type in use:

3.1.  Not every wet lacquer type is applicable for induction curing system due to the fact that the heat up ramps are much faster than with a gas curing system

- For a list of recommended (and pricewise competitive!) lacquers contact Can Man

3.2.  The correct viscosity and therefore the proportion of solvent is most important for a non-porous side seam protection.

- For further information and / or support contact Can Man.

Possible cause:
Sparking on the induction coil

  • Make sure that there is a clearance of 3–5 mm between the coil and the canbody!
  • Make sure that the cooling water temperatur setting is correct (> 25°C) and you have no condensation at the coil. Condensation could cause a short circuit!

HF filter not set correctly (to high)

  • Check setting of PLL stfreq and HF filter. HF filter must be set 10KHz higher than the PLL stfreq. Go to the “system setup” to check.
    Note: The setting is password protected. If adjustment is needed, please contact Can Man.

Check all insulations of the coil and C-bar.

  • Download PDF here for more details!

Possible cause:

There might be a loose connection!

 

Check the connection of the plug J1 on the main board (see picture).

Check the voltage on this plug while running:

white -> black = 0.5 – 1.0 VDC

green – > black = 15 VDC

brown -> black = -15 VDC

 

If you don’t have 0.5-1.0V, please check the wiring of this cable, which goes to a small board inside the of the PM HF.

NOTE:
Check this plug only when the unit is switched off and discharged!

Cause:

The water flow of the coil is too low!

NOTE:
The standard setting for this error is 3l/min (can be found in the basic setup “rotary minflow”).

 

The actual water flow is shown in the display. Press down from the main menu on the display until you find the flow coil.

NOTE:
You have to switch “ON” the curing to open the water valve!

Check for possible causes:

  1. Check correct connection of inlet and outlet!
  2. Clean inlet water filter.
  3. Check your input pressure, you shouldhave about 5 bar.
  4. Check if a water tube is bended ordamaged.

 

Clean the water valves:

Therefore disconnect the water inlet to the Pacemaker HF and blow out the water. Take off the coil and open the valve with a torx screwdriver. Blow out the valve and clean the rubber.

 

Reassemble the valve properly (insert the closing block with the spring on top, so the rubber is closing the outlet hole.

 

Clean the rotary flow unit. Follow the instructions below.

 

  1. Disassemble device by grabbing lens center hex with 7/16″ socket and turning 45° counter-clockwise. Pull on lens to unseat. Dismantle internal components.
  2. Clean body interior (rotor cavity and o-ring gland).
  3. Lube o-ring.
  4. Install o-ring to body o-ring gland.
  5. Install shaft to body.
  6. Install rotor to body on shaft (on top of washer).
  7. Install lens to body.
  8. Turn lens 45° clockwise to lock it.
  9. Pressure test to 50 psi to proof o-ring integrity.

If were not successful, replace the rotary flow meter => CM article No 007906

 

Possible cause:

  • Check whether the powder already was falling off, before the canbodies did enter into the PowerCURE™.
  • The transport belts are not running steadily:
    • Check whether the belt from the motor to gearboxes is jumping over.
    • Do not tension too much, tension till the belt is not jumping over anymore.
  • Take off the belt from motor and both transport belts, and check the play of both gear boxes:
    • The internal worm gear might be broken.
  • Grease the guides of the transport belts to reduce the friction.
  • Check whether the transport belts are moving straight into the guides:
    • The belt is possible touching left or right of the groove.
  • Check all wheels and replace the bearing when not turning smoothly.
  • Increase the transport belt speed.
    • Please check the curing after increasing the speed as this might require a bit higher voltage adjustment, however the consumed energy is the same.
  • Check whether any screw from the frame or any of the feet has become loose.
  • Check, if the motor/gearbox of the conveyor drive is grounded. Only applicable for latest model.
    • If not, ground the motor/gearbox.

Water quality:
pH value: 7–9
Conductivity: 50–60 µS/cm
Total hardness: < 14 °dH
Filter: max 150 µm

The reset LED flashes and a warning is shown!

If the reset LED flashes, then the system works in a critical state. The unit is still entirely functional, but it should be a hint for the operator to do something against the warning.

Contact Can Man for advice!

Possible cause:

  1. Check the water flow. Is the water flow reduced compared to before!
  2. Clean the external filter.
  3. Do you have a drop of pressure compared to before?
  4. Check the water quality.
  5. If you have increased the power, it could be, that the water temperature at the C-bank is higher than before.
    • you might increase the flow – contact Can Man for advice
      (only for CM technician turn the restrictor / valve by an eighth of a turn).

Please check on the white transformer all connections.

 

ATTENTION:
Switch OFF the main supply first!

 

Nuts must be firmly tightened, but do not overtight! Bolts must well fixed in the casting compound.

 

NOTE:
A loose connection creates an overheating and destroys the transformer and cables!

Don’t worry, due to the induction process is this absolutely normal.

Possible cause:

  • Between touchscreen and frame there might be dirt or the airgap is too small.
  • Touchpanel defect.
  • Scale of the touchscreen surface is not correct.
    Contact Can Man use E-ticket.

Download PDF here

German instruction: page 52 – 55

English instruction:  page 110 – 113

French instruction:  page 172 – 175

The IC, which control the analog output, must be replaced. Please request support from Can Man!

Possible cause:

  • Battery voltage low = DC voltage across the chopper too low
  • Supply voltage mains (all three phases) 400V
  • Check main contactor K1 all connections tighten
    If you doubt the functioning of the contactor , replace it with the same type.
  • After loading and switching on the MS signal (K11 in the control), the main contactor (K1) should switch on and there should be 400V at the out put of the contactor.
  • Measure the voltage over the battery / capacitors in the standby condition. (min. 400 VDC)
  • Check the fuse at the 24V power supply (F1..F5)
  • Check if the relay K3 and K4 connections and plugged properly
  • If the message arises sporadically after a certain time, the receiver on the HF controller is probably defective. => Contact Can Man

CAUTION – HIGH VOLTAGE:
You are now in the immediate vicinity of parts that produce high electric voltage! There is a danger of an electric shock.

Only performed by “certified electricians”

 

  • Measure the voltage on the clamp J5
  • =>if the power output is set to 50V it should have about 100mVDC. (Running with curing “ON”)

Measure the voltage on the main board clamp 57=”+” 58= “-“ => if the power output is set to 50V it should have about 100mV.

• Check if the Dc-Dc IC has a problem you can exchange it with an other one on the board
(which is unused in your configuration – remove the IC carefully, so the pins are not getting damaged!)

  • If the measurement is still lower than 100mV, you have to replace or repair the C-Bar. (Can Man No. : 019817)
  • There is a problem on the voltage divider on the C-Bar (R1..R12). One of the welding pointsπ or SMD resistors are bad or damaged.R=150 kOhm
    among end of R1 and J5X : 900 kOhm among end of R7 and J4X : 900 kOhm

Yes, download the PDF document here

  • 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!