Support

43 Support Entries

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.

The reason for a wrong decrement counter can be a reset during production. 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.

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!

 

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.

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

 

 

 

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 !

 

Download PDF here

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.
    • Please contact us for further instructions.

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.

Download instruction

Possible Cause:

  1. Check air supply for the cylinder.
  2. Second light barrier is always ON.
    Sensor dirty or bad adjustment.
    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!!!

Download PDF english

Download PDF chinese

Possible cause:

  • the welding roll might be defect
    • change welding roll
  • in case you use a mercury based welding roll
    • add some mercury
  • the pendulum roll might be defect
    • change the pendulum roll
  • in case you use a mercury based pendulum roll
    • add some mercury
  • 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.

 

  • 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.

 

Check also the input directly inside the PM.

 

QM board defect?
A reason for a voltage error could also be a defect on the QM board, which receives it’s supply from the elec. board of the PM.
To verify a defect you can remove the supply cable. The voltage value should go up around 20V (e.g. 375V to 395V), which is normal. If the increase much bigger than 20V the QM board has a defect and need to be replaced.


The voltage value on the touch screen is much lower than on the main terminal!

As a matter of fact, this electrical balancing of the two values has been done by CANMAN prior to the delivery. If there is a discrepancy you can adjust it.

 

You have to lose the small electronic board of Qualimaker (if applicable). This board is supplied by the big electronic board of PM. If you remove this supply cable, the voltage value goes up around 20V (e.g. 365V to 385V), which is normal.

 

Now measure the input of terminals, for example 385V. Turn the small blue potentiometer (picture). Control the value on touch screen. Must be around 20V more than the measured value, if you have a QM board. If you have adjusted it, connect the supply of QM and now you have the correct value on touch screen.

 

NOTE:
Starting with the version of the V4 mainboard, the board has two potentiometers. You need to adjust the “UMains” potentiometer in this case.

FAQ – Trouble Shooting

For the correct function of Qualimaker please check the 3 LED’s:
LD16 = state of profibus connection, must be on every time.
LD1 = program state, must be on every time.
LD2 = clock(cycle) of program, must be blinking.

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!

  1. Check if there is a higher trafo step
  2. Lower the freqency if possible
  3. Check machine insulations

Check the fuse on the bottom side, near the mains electrical (only PM 400/500 – PM Micro has no fuse!)
Check also the cable on this holder, it might have bad or oxidised contact!

DO NOT USE LARGER OR FAST TYPE OF FUSE!

 

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

CM article No. 008052

NOTE:
These surge suppressors are only built in to the latest PM models (from 2009).

 

Make sure that you do all the actions with the necessary care and that all manipulations and measures are done by a certified electrician and with a well insulated multimeter! However do not manipulate inside the unit before the front panel display shows a low U batt (<24V)-(condensator battery voltage)!

 

With main switch on, switch on the inverter and monitor the charging of the battery voltage (Ubatt).

 

If battery voltage does not at all increase, you may check the function of the “small precharge relay” and its output on the main board.

 

There is an LED (LD25) on that output showing the state of this output. If the precharge relay doesn’t react you may check the wiring.

 

If the battery voltage increases, but the “precharge time out” appears while the voltage is still increasing, it could be that.

a) a phase is missing or has an “under voltage”, therefore you should check the voltage of all three phases (also to ground!)

 

b) it could be that the rectifier (1) or even worse a condensator or an IGBT (2) is malfunctioning.

 

Measure the actual battery voltage and compare it to the display (Ubatt). (ATTENTION: Switch off the unit and wait ’til the battery voltage is low, before you remove the front cover!). The voltage could be beyond 550 Volt DC, so please use a voltmeter, which has the necessary range. The terminals are on the left top (usually red and blue coloured).

 

During loading, check the LED on the power board, which connects to the condensers. Are they glowing up at the same time? After loading are LED’s still on?

If not one more condensers might bad or defect!

 

To check the condensers, you can measure the resistance with the Ohmmeter, between the relay contact “14” and the recitfier (red wire) and contact “24” and the recitfier (black wire) – see picture beside.

 

The result should be 68.0 Ohm.

Possible cause, the signal “reduce current” is always active. With reduction switch on there is no measuring, that means “Ctol” and “Power Limiter”are not active.

Check the signal “reduce current”. Maybe the electronic card of the machine is defective.

Change of the processor board

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

IMPORTANT:
Before you start to change the board write down all values/parameters (e.g. main current, frequency etc.) for each can you have saved in pacemaker memory.
This not necessary for the CMX1 and X8 welder, because the parameters are safed in the panel.

 

Switch of main switch of pacemaker / machine.

 

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.

 

Be careful about the board position and especially the position of the connectors.

 

NOTE:
Depending on your current Pacemaker version you have to change the MAX IC as well.

 

The MAX IC controls all outputs and IGBT`s and works also with a software.

 

NOTE:
To remove the IC, use the delivered special tool. Never use a screwdriver or another tool. You will destroy the socket!

 

Take MAX IC out with the designated tool.

 

Install the new MAX IC.

 

Double-check the position before you press the IC in the socket!

 

Switch the main switch “ON” and check all parameter (current, frequency, etc.) before you start production.

Check the main supply
R-380VAC (L1), S-380VAC (L2), T-380VAC (L3).

 

Check if all green LED’s are “ON”.


Check in the display of pacemaker the actual displayed voltage R, S and T! (old version PM)

 

If you can see these values and one of them looks to low, you can adjust it with the three small potentiometer on left side of processor board (old version PM).

  • Check sensor on tool
  • Check setting of t2 and t1
  • Check input of reduce current signal. LED of input 4 of pacemaker board.
  • Check light barrier of eject station, maybe wrong adjustment or dirty.
  • When the cans passing the light barrier of the eject station, the gap between the cans must be bigger than 10 mm.
  • Additionally check the following possible causes here.
  • Check can memory. Must be “0”, if there is no can between welding area and the reject station. For reset memory activate light barrier by hand or  use function “reset can memory”.
  • Check sensor on tool or light barrier.
  • Never take out can between welding area and eject station.
  • Check condition and setting of the machine.
  • IReg Max too low.
  • Setting of the Qualimaker.
  • The message “jam in welding section” means the welding sensor B6 is on for 4 seconds without switching on and off. In normal production the sensor is switching on and off for each can.
    • Check the function of the sensor!

If you have connect the control panel and you can see only strange signs in the display, the connecting speed can be wrong. The Pacemaker control panel can run in two modes.


19200 baud

Control panel standard is 19200 baud (Used for connecting between control panel and PLC )

9600 baud

9600 baud (Used only for connecting between PLC and Pacemaker)

 

How you can change to 9600 baud:

Switch off the Pacemaker (Main switch off)

Press the “MENU” button while starting the panel.  

Now the control panel runs with 9600 Baud Can Man machines with PLC.

 

How you can change to 19200 baud:

Switch off the Pacemaker (Main switch off)

Press the “RESET” button while starting the panel. 

Now the control panel runs with 19200 baud
Control panel and PLC.

19200 baud

Control panel standard is 19200 baud (Used for connecting between control panel and PLC )

9600 baud

9600 baud (Used only for connecting between PLC and Pacemaker)

How you can change to 9600 baud:

Switch off the Pacemaker (Main switch off)

Press the “MENU” button while starting the panel.  

Now the control panel runs with 9600 Baud Can Man machines with PLC.

How you can change to 19200 baud:

Switch off the Pacemaker (Main switch off)

Press the “RESET” button while starting the panel. 

Now the control panel runs with 19200 baud
Control panel and PLC.

Cause 1:

The setting of t1 and t2 is wrong. If the timing is wrong the PM cannot execute the signal, which is necessary to memorize the canbodies in the reject unit and to start the record of the graph.

Setting of t1 and t2:

t1 defines the starting point for the reduced current time window. 

t2 is the time, where the reduced current windows ends. t2–t1=isthusthetimespanforthe reduced current, therefore t2 > t1! 

 

NOTE:
The value of t2 and t1 need to be smaller as the cycle of one single can.

For example:
A production of 300/min. corresponds to a cycle time of 200 ms/can. Production of 600/min. corresponds to 100ms/can.

 

NOTE:
For a more detailed explanation of timing t1 and t2, consult your manual book 2, chapter 5.6.5. “Setting of Parameter t1 & t2 for recuded Current and Overlap Check“.

 

Cause 2:

Check the inductive proximity switch B64 at the final pusher unit for function, operating distance and defect.

 

B64

Final pusher (Synchrostar II): Sensor B64.

 

Description:
Inductive proximity sensor for embeddable mounting.
Polarity: PNP
Output: NO. or NC.
Operating distance: 2mm

 

Cause 3:

Check the tool switch B6 in the calibration tool for function, operating distance and defect.

 

B6

The position of the welding sensor B6, can be almost flush. Just make sure that you don’t get scratches on the canbodies.

 

The height of the sensor can be adjusted here (arrow).

 

Inductive Sensor (magnetic field resitant)

Mounting mode: flush
Function principle: inductive/normally open Rated operating distance: 3 mm