Support

Problem:

Circuit breaker Q5 trips when the machine is switched on or during production.

Possible Causes or Resolutions:

• Measure voltages at all phases, even under load. It is possible that one phase did drop down, and this triggered the circuit breaker.
• Measure the current of each phase with a current clamp after Q5. If the measured value is below the value of the circuit breaker and Q5 still keeps tripping, the circuit breaker may be defective. Replace it.
• Maybe the parameter “Low bat voltage” (coming from Pacemaker) is set too low: That means that the contactor in the Pacemaker closes too early with a precharge voltage that is too low and therefore Q5 trips. To check this, please open a ticket to contact CanMan.

Download Checklist setting overlap X7

Problem:

All drives are starting correctly, but the vacuum and welding current are not active.

Possible Causes & Resolutions:

• Welding pressure has been set below the min. value of 2.0 bar => Check the welding pressure setting value on the precise air-regulator and reset if needed.
• Solenoid valve welding pressure Y10 does not work correctly  => Check the welding pressure valve Y10. Does the valve switch correctly and do the welding rollers close?
• Welding rollers are closing and welding pressure is set correct, but no welding pressure value is displayed on the HMI => Check whether the analogue sensor B77 is working correctly or not.

Problem:

Some Beckhoff i/o terminals are not active and status LEDs are off, control does not respond to commands.

Possible Causes & Resolutions:

• The 24Vdc supply of the EK1100 coupler or the EL9410 intermediate supply terminal is missing or the voltage is too low > Check all connections, measure voltage, check fuses.
• Bad contact between the terminals > Switch off the main power and remove the terminals. Clean the contact between the terminals.
• Defective EL9410 intermediate supply terminal > Exchange terminal.
• Defective EK1100 coupler > Exchange coupler.

Problem:

• Welding process starts but welding current is not constant. Finally the welding wire breaks.

Possible Causes & Resolutions:

• Bad condition of the lower welding roller or upper roller head. In this case, the current only flows through the welding wire and no longer over the welding roller or upper roller head. The welding wire heats up and breaks. Exchange lower welding roller. If the problem still exists, replace the upper roller head.

Problem:

After main switch off and on again, HMI piece counter values and settings are lost or old recipes are loaded.

Possible Causes & Resolutions:

• IPC has not shut down correctly.Check the IPC after you switched off the main switch: Normally it will continue to run for at least 30 seconds to shut down correctly. If LED’s of IPC goes off within a few second, the battery of the UPS – unit is dead and needs to be replaced.

Problem:

During production, the error message “over temperature upper current conductor” appears. This means that the cooling is no longer sufficient to keep the upper current conductor constantly below 40 degrees Celsius.

Possible Causes & Resolutions:

If the cooling unit is working properly (temperature and pressure is OK) and no flow switches are giving an error, then contamination is most likely the cause of the problem.

Clean the cooling circuit, especially the cold-water circuit in this case, including the cooling unit. Check the water level in the cooling unit and top up if necessary and replace lubricant (if PowerROLL – coolant or DISCON is used) and clean the cooling system as recommended every 6 months.

Cooling emulsion exchange and cleaning

Problem:

Downstacker motor doesn’t move correctly to the reference position, stops or suddenly changes the direction of rotation. Display of servo controller U16 shows „IMax“ or „P03 trip“.

Possible Causes & Resolutions:

To check:

• Mechanical condition of downstacker motor: Turn it by hand and check that everything runs smoothly.
• Resolver mounting: Is firmly connected to the motor shaft?
• Resolver bearings: Remove the resolver from the motor shaft and check if it is turning smoothly.
• Resolver and motor connections: Motor and resolver are connected correctly and clamps/plugs tightened?
• Motor windings: Disconnect the motor from the inverter and check the windings with an ohm meter (U-V,U-W,V-W). All values are equal?
• Output servo controller: Measure the inverter output voltage when it should run (U-V,U-W,V-W). If 0V and display shows „IMax“ maybe servo controller defective.

Problem:

Machine stops and message „Pacemaker: Profibus communication error“ is displayed.

Possible Causes & Resolutions:

• Cooling water valve: Wrong type of valve or plug without protective circuit (suppressor). The voltage peaks can cause interferences in the Pacemaker electronics. Always use the original plug and valve type.
• Profibus plug: On the plug of first and last client of profibus system the termination resistant must be set to ON. Otherwise interference may occur.
• Profibus cables: Check the position of the cables in the control unit. If they are close to contactors, high voltage peaks can create interferences.

Problem:

The HMI cannot be started and the browser shows „NOT FOUND, The requested URL /en/default.htm was not found on this server“.

Possible Causes & Resolutions:

Not connected to Canman Wifi (only for wireless connected iPad’s): Check the wifi settings. Choose Canman wifi and try again.

IPC has not shut down correctly: In this case probably the HMI software can’t start up automatically by restarting the machine.

Check the IPC after you switched off the main switch: Normally it will continue to run for at least 30 seconds to shut down correctly. If LED’s of IPC goes off within a few second, the battery of the UPS – unit is dead and needs to be replaced.  Contact Canman for online support to restart HMI.

Possible reason:

• Check the blank cutting tolerances (can be supplied by Can Man): If the cutting tolerances are to big, the blanks will create all kind of downstacking errors.
• Check the burrs on the blank: If the burrs are to big, the blanks will create all kind of downstacking errors.
• Check the setting of the separating air: If the separating air is to low, the blanks can not being pulled down correctly. Try with more or less separating air.
• Clean the slider of the Linmot pusher according the manual.
• Magnets in the base plate might brake the blanks to much: Can Man does equip each base plate with 4 or max 6 magnets, depending on the the blank size. Remove eventually 2 magnets.
• Check the clearance of the first rollformer roller pair: The clearance between the lower and upper roller might be too small. Adjust the value according manual.
• Check the “Quick Change Level 40mm” setting acc. below pictures on the HMI: If the distance between the blank stack and the base plate measures 30 mm, set the function “Quick Change Level 40mm”  to OFF. If you measure 40mm, set it to ON.

• Check the vacuum-stop point: The process to stop the vacuum must be activated by the mechanism around 3 mm before the blank arrives at the base plate. Please check the manual how to set.
• Check if the supporting air-pressure to stop the vacuum is adjusted correctly: Check the value / setting according the manual.

Problem:

Canbody transport motor doesn’t move correctly to the reference position, or stops, or changes the direction of rotation, or the display of the servo controller U7 shows „IMax“ or „P03 trip“.

Possible Causes & Resolutions:

To check:

• Mechanical condition of canbody transport motor: Turn it by hand and check that everything runs smoothly.
• Resolver mounting: Is firmly connected to the motor shaft?
• Resolver bearings: Remove the resolver from the motor shaft and check if it is turning smoothly.
• Resolver and motor connections: Motor and resolver are connected correctly and clamps/plugs tightened?
• Motor windings: Disconnect the motor from the inverter and check the windings with an ohm meter (U-V,U-W,V-W). All values are equal?
• Output servo controller: Measure the inverter output voltage when it should run (U-V,U-W,V-W). If 0V and display shows „IMax“ maybe servo controller defective.

• Machines with lift table and non-stop: Check whether the white gear wheel on the encoder shaft of the downstacker motor is fixed on the shaft by the M3 grub screw. Make sure that the grub screw is aligned to the flat surface on the shaft.

Problem:

• Welding process starts but no welding current.

Possible Causes & Resolutions:

• Condition of lower welding roll: Possibly the roll is worn out or mercury very old. Refill mercury or exchange lower welding roll.
• Condition of upper roller head: Possibly the roller head is worn out or mercury very old. Refill mercury or exchange upper roller head.
• Waterflow: The green button for welding current on/off must light up when the water flow is ok. If not maybe the water flow is to low. Check also the relay K21. If water flow is ok this relay has to be on.
• Welding pressure switch S31: If welding rolls are closed the switch S31 do enable the welding current. If the welding pressure is adjusted to low or also to high the control do not enable the current. Do adjust the welding pressure correctly according manual.
• All connections of current conductors on secondary side of welding transformer: All screws must be tightened. If there are signs of corrosion, disassemble parts and clean the contact surfaces.
• Connection between head piece and lower welding arm: Remove the head piece and check the contact surfaces.

• Fine-wire fuses F2, F3 and F4: This are located inside control. Check them with ohm meter and replace if necessary.
• Transformer T4 (18-0-18V): Measure the outputs of small transformer inside control. The easiest way to do this is to measure it at the terminals of the WEC card. c32/c30 => 18VAC, c32/c28 => 18VAC, c28/c30 => 36VAC
• WEC electronic card: Firmly inserted in the card holder?
• Thyristor: Maybe thyristor module is broken.

Problem:

• HMI communication error (see picture)
• Not able to run the welder

Possible Causes & Resolution:

Excel Spreadsheet – CM Electrical Components List

Problem:

• Speed of the drives changes during production

Possible causes & resolutions:

• Wrong position of the switch for the terminating resistor on the bus plug.
  Check all switches on the complete bus system. Follow the cable thoroughly from first DP bus device (PLC) to last DP bus device. The terminating resistor switch of first and last must be set to „ON”, all other to „OFF“.
• Bus connector/plug defect
• Check wiring of all profibus cables, especially the connection of the cable shield inside the plug.
• Problem of terminating resistor supply by last device on bus. Try to change the profibus wiring to use on another device as last client.

Problem:
Display shows „Could not activate iPad“

Possible causes & resolutions:

• No internet connection > Check network connection of machine.
• Firewall blocks connection to iPad > Try to connect the iPad to other Wifi without firewall, for example hot spot of mobile phone.
• Try to make a reset by holding down the home and power button simultaneously for a few seconds until the Apple logo appears. Don’t worry, the iPad doesn’t have any data inside, it only displays the values from the browser. Can Man does not use an Apple ID to activate the iPad’s, so the iPad is resettable.
• iPad might be defective > We will offer new one or you organize it locally.

For connecting an alternative display / PC, please have a look at the separate FAQ.

Please follow the below instructions carefully:

1. Cooling unit for cold water (for both welding rollers):

• The cooling emulsion must be changed yearly, but more preferably every 6 months. Follow the X7 manual if you have to change the emulsion !
• The filter cartridge of 50 µm needs to be replaced monthly ! Follow the X7 manual if you have to the filter cartridge !
• Check the level of the cooling emulsion on the internal tank. If you have to refill the tank, follow the X7 manual to get the correct mixing ratio for the emulsion, and fill the tank. Note: If the water level is too low, the chiller should show an error message, and the X7 should stop and show an error on the iPad !

2. Cooling water / emulsion distribution station on X7:

• Run some (5 to 10) can bodies and control the water pressure on the manometer: 5.0 bar is the min. required water pressure !
• Run some (5 to 10) can bodies and control the water flow on the flowmeter S26 (2. From right side): 5.0 liter per minute is the min. water flow.
• Note: The water pressure switch S120 is set to > 4.0 bar. If there is the error message “Error S120” on the iPad , first check the water pressure on the manometer, and if it’s below 4.0 bar check the cooling unit again !

3. Weld roll ø 42 / 49 / 54 / 62 / 90 mm and lower weld arm:

• It’s possible that the cooling circuit from waterflow meter S26 to lower weld roll, and back to the outlet on the water distribution, is blocked:

Take off the lower weld roll, unplug the grey water tube ø 10 mm labeled with “àWR” directly at the flow switch S26, and blow into the tube with air pressure. Check the out-going air-pressure at the free hole in the lower weld arm (supply for lower weld roll). If the circuit is free, you feel an equal air pressure (like on the output of the air gun) on your finger tip. If you recently took off the lower weld arm, there might be a problem with one or both o-ring seals between arm and upper bus bar:

Please check them if needed !

• Now unplug the grey tube ø 10 labeled with “WR à” on the water distribution and blow into the tube with air pressure. Check the out-going air-pressure at the free hole in the lower weld arm (exit of lower weld roll). If the circuit is free, you feel an equal air pressure on your finger tip
• If you re-install the lower weld roll again, make sure that the arrow “running / turning direction” is showing into the right direction.

Before re-connecting both grey tubes ø 10 mm, blow into one tube again by air-pressure, and feel the equal air-pressure on the other tube by your finger tip. If it’s ok, correctly connect both tubes again.

4. Copper wire / copper wire profiling unit:

• Measure the copper wire profile after the profiling unit on various positions (within around 300 mm). Check the correct width in the X7 manual. The tolerance must be within 0.03 mm !
• Please check if the wire guiding wheel in front of the lower weld roll is broken. If it’s broken, replace it by a new one. Make sure you choose the correct size 1.90 or 2.30 mm !
• Please check if the copper wire tension is correct. Set the correct tension according X7 manual !

5. Welding parameters:

• Please check the weld pressure. Set the correct welding pressure according X7 manual. The range should be between 40 and 50 daN.
• Please check the welding frequency. Set the correct value according the recommendation in the iPad !
• Please check the welding overlap. The welded overlap should be nosepiece overlap + 0.1 mm !
• Check if the IR-Sensor graph of the Qualimaker 2™ on the iPad are within the correct range and straight, which means that the crown and exit conveyor settings are correct:

6. Other possible errors:

• If the copper wire gets burned, check if the upper and lower weld roll are touching each other without a blank between. Press the button on the main-aluminium plate to close the welding roller and test it.

Problem:

• Welding process does not start or starts too early before the welding rollers are closed and burns a hole in the can.

Possible Cause:

• Wrong signal of welding pressure switch. The start of welding current and transport is activated by a digital pressure switch S31 installed on the air regulator for welding pressure. If the welding rolls close and the digital pressure switch reach the programmed value the welding does start.

Check:

• Is the setting of welding pressure correct?
• Does the welding pressure cylinder work fine? Does it open and close smoothly?
• Does the welding pressure switch work properly? The switch must switch on when the welding pressure is between 1.5 and 3.0 bar. 

Weldingroll_Dimensions.pdf

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:

• Replace IPC battery with Lithium Battery Type CR 2032
• Replace battery according to the Beckhoff Instruction (Access to Battery)

Download regrooving datasheet

Download PDF here

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!

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

• If the Led are not switching off after machine power off (wait at least 5min. !), remove the X101 plug on the IPC and plug it back after some seconds.

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 (HMI app) and wait for >2 min.
Now you should be able to open the HMI without error message.

Closing apps on iPads with a home button:

1. Double-click the Home button to show your most recently used apps.
2. Swipe right or left to find the app that you want to close.
3. Swipe up on the app’s preview to close the app.

Closing apps on newer iPads without a home button:

1. From the Home Screen, swipe up from the bottom of the screen and pause in the middle of the screen.
2. Swipe right or left to find the app that you want to close.
3. Swipe up on the app’s preview to close the app.

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:
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.

See also in the manual X1 how to reset the upper pendulum rollerhead.

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!

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.

• 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!

Download PDF

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 and machine controls (from 2009).

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

Attention!!!

Do not bridge the signalling contacts and run the machine with defective red modules because they no longer protect the system from voltage peaks!!!
If the modules are defective, check the main supply. Measure and check all voltages between the phases and all phases to earth before exchange the modules and restart the machine.

Download PDF english

Download PDF chinese

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

Possible cause:

• Check if the blank cutting is correct.
• Check if the overlap is correct and constant.
• Check the welding sensor B6.
• Check the welding pressure sensor S31:
  • depending on your version S31 is a pressure sensor or a reed switch!
• Check if the wire has no dent’s (mechanical damage for example due to too big can gap).
• Check all terminals at the Pacemaker board.
  • > wait for 5 minutes after switching off the unit.
• If you can weld a canbody with only main current and the error occurs quiet often, you can try the following:
  • a) remove the welding sensor.
  • b) start production and cover the sensor by hand, as soon as canbodies are welded.

• Open the rollformer, and put a piece of wood between the rollers (for safety)
• Only if weld pressure by spring: Release the spring pressure of the welding pressure completely
• Stop the main air supply
• Switch of the main power supply
• Stop the cooling unit, take off both water pipes from the lower weld arm (long copper bus bar)
• Take off the lower weld arm by taking off the copper plate (on transformer side) and loosen all bottom M5 screws.
  It might be needed to take off the idler wheel in front of lower weld roll as well
• Undo both bottom M5 screws (type: Flat head, thickness 1.5 mm) of the T Z-bar
• Undo both M6 screws (through side plate of rollformer) which is holding the support above T Z-bar
• Undo four M5 screws which are holding the T Z-bar over its top support
• Clean the slot in which the T Z-bar is going in by air pressure if needed
• Clean the surface on the rollformer side plate if needed. Don’t use sandpaper with your fingers. If needed use a grinded plate to support the sandpaper.
• Grease the T Z-bar and the slot and mount the T Z-bar by the bottom two M5 screws. Don’t tight them yet!
• Mount the top support by four M5 screws, and push the support (and T Z-bar) towards the rollformer side plate
• Check now the top and bottom gap between side plate and support by feeler gauge 0.02 – 0.04 mm: There shall be no difference
• If there is no gap, tight first the bottom screws, then top screws, then screws through rollformer side plate
• Undo the bottom screws and tight again
• Clean all bottom flat head M5 screws if needed (they become rusty), and grease their heads
• Mount the lower weld arm. Make sure that the insulations of each screw are not damaged. Lubricate each insulation if they are made by shrinking tube
• Put a piece of paper board between the weld rolls and measure the insulation
• Connect the lower weld arm on the transformer side by mounting the copper plate between and connecting the water pipes
• Switch on water, air and power supply
• Feed in the profiled copper wire compeletely
• Only if weld pressure by spring: The gap between both weld rolls shall be not bigger than 2.0 mm (enough to feed-in two profiled copper wire). Adjust if needed by the M6 threaded bolt / nut
• Adjust the air-throttle on the weld pressure cylinder to make sure that the piston is coming down as slow as possible!
• Test it first by activating the solenoid valve
• Only if weld pressure spring: Adjust now the spring: If the weld rolls are closed the compressed spring shall have a length of about 55 mm (length of uncompressed spring
  measures 80 mm. 5.5 mm are equal to 10 kg / daN)

• Take off the copper wire completely.
• If powder tubes are in use, take them off too.
• Take off the nosepiece, and clean its positioning slot very carefully!
  Special attention is needed in the area of the front pin.
• Measure the resistance between lower welding arm and the Z-bar support/long Z-bar.
  • The restistance must be endless.
• If the measured value is too low, take off one after the other screw underneath the lower welding arm.
  Attention: Do not take off all screws, the lower welding arm will fall down!
• Check if every screw has an insulation ring and tube.
• Blow off all holes by air pressure.
• Check if the long insulation stripes on each side of the Z-bar are in.
• If the restistance is still not good, the secondary unit may have somewhere else a contact with the ground.
• Check the hole secondary circuit.
  • The secondary circuit must not be connected to the ground!

Possible causes:

1. Welding pressure:
   Is the welding pressure mechanically always guaranteed?
2. Upper roller:
   Is the upper roller touching the Z-bar?
3. Lower welding roller:
   Is the lower welding roller too low?
   Welding center must be in the center of Z-bar!
4. WEC-O3 circuit board:
   Change the existing with a new one.
   
   Attention: Make sure all jumpers and all little blue pontentiometers are in the same position!

Possible cause:

• Check the unprofiled copper wire in the drum: The copper might be already oxidized.
• Is the welding current setting as usual, or is there any difference?
• Check the water flow of the upper pendulum rollerhead, and also the lower welding roller.
  • see also Lower welding arm/welding roller get warm/hot.
• Check the colour of the lower welding roller:
  • If the roller is yellow/blue/purple you should exchange the roller. There might be an internal defect. Send the roller to us including a correctly filled out performance sheet.
• Run the welder after exchanging the roller and/or water flow check, and control, if there are any abnormal hot spots on the secondary circuit.

NOTE: There are two type of wire tension systems for the CM16:

• CM16 – 300/400 has two pressure gauges.
• CM16 – 200 works with one pressure gauge and a spring tension system.

Possible cause:

1. Try to move the tension cylinder / cylinders by hand back and forward, without air pressure and wire.
2. Try to turn lower welding roll (without wire) by hand.
3. Check the groove of the upper welding disc.
4. Is the wire width correct?
5. Adjust the pressure of the tension cylinder(s), read for more info here! Cylinder below wire profiling unit requires 1.6 bar. Cylinder (behind main alu-plate) for wire chopper unit requires 2.0 – 2.4 bar.

Download PDF here

Possible cause /checklist:

• Check all terminals at the Pacemaker board.
  • wait for 5 minutes after switching off the unit
• Check welding sensor (position/exchange).
• Check the piece counter in the display. If more canbodies are counted, than there are physically – there is a problem with the welding sensor.
• Check the welding pressure: Is S31 always „ON“ (LED green) / Display > 30.0 daN!
• If the welding pressure is secured, you can bypass the signal with a trial jumper, see diagram page 2:
  • a) remove and insulate terminal 5 of the PM.
  • b) jumper terminal 1 > 5
    Do this only for the trial, need to be reversed afterwards!
• Are the time settings t1 and t2 correct?
• Is the weld power limiter switched „ON“? Which mode is chosen? Glueing?
• If you can weld a canbody with only main current and the error occurs quiet often, you can try the following:
  • a) remove the welding sensor.
  • b) start production and cover the sensor by hand, as soon as canbodies are welded.
    Important: Switch “OFF” the sensor before you open the welding pressure!
• Check if the wire has no dent’s (mechanical damage for example due to too big can gap).

Possible cause:

• Check whether both pneumatic cylinders do have the correct air pressure:
  • a) Pneumatic cylinder for the profiling unit: 1.6 – 2.0 bar
  • b) Pneumatic cylinder for the wire chopper: 2.8 – 3.0 bar
• Check whether sensor B1 and/or B2 touch the slant activation plate.
  • The sensor positions/heights are well adjusted, if the piston rod on each cylinder has about 10 – 15 mm remaining stroke left!
• Exchange the sensors B1 and/or B2.
• Exchange the standard I/O module of the frequency inverter U6 because the analogue input could be defective.

• Check whether the plug or cable of B1 and/or B2 have any damage, or are not well connected to the frequency inverters.
• Check whether, there is any error message on the frequency inverters U3, U4 and/or U6.

• Check the mechanical play between both upper/lower brass guides (one for the profiling unit is mounted on the main alu-plate, the second is  mounted on the alu-plate above the rollformer) and the support of the idler wheels.
  • There must be a clearance of 0.3 – 0.5 mm on the whole stroke!
  • Use a feeler gauge to adjust the clearance.

• Check the profiled copper wire width according manual.
  • If the width is unstable, the main bearings in the profiling unit might be damaged!
  • Take off the copper wire, and turn the motor through the fan impeller on top. If the bearings are broken you probably can feel it, or try to feel the bearing play, by moving the profiling rings up and down.
• While the copper wire is off, check whether all idler wheels are turning well or not.
• Check the clearance between both transport rings on the wire chopper according manual.
  • Basic setting: Clearance should have 50% of profiled copper wire width!

Possible cause:

• Check your welder according check list 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.

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.

http://support.apple.com/kb/TS3281

Symptoms

Your iPhone, iPad, or iPod touch may occasionally stop responding to buttons, switches, or touchscreen input and may exhibit one or more of these symptoms:

• Does not return to the Home screen after you press the Home button
• Does not wake from sleep after you press the Sleep/Wake button
• Does not turn on (or power on) when you press any button
• Does not start up past Apple logo
• Appears frozen or unresponsive
• Is unable to “Slide to Unlock” or “Slide to Power Off”

Resolution

1. If a single application is not responding or stops responding when it opens, you can force it to close.
2. If the device is unresponsive or if certain controls aren’t working as expected, restart your device.
3. If the device remains unresponsive or does not turn on (or power on), reset your device.
4. If there is no video or if the screen remains black, verify that the device has enough charge to turn on:
   1. Ensure that the iPad is connected to the USB Power Adapter supplied with the device.
   2. Let charge for at least twenty minutes, then see if it starts normally.
   3. If there is no image on the screen, press the Sleep/Wake button to attempt to wake the device.
   4. If the screen displays a red battery icon, continue charging the device until the battery is fully charged.

Troubleshooting touchscreen response

http://support.apple.com/kb/ts1827

Symptoms

Use this article to troubleshoot the following Multi-Touch display (or touchscreen) response issues:

• Multi-Touch display (or touchscreen) does not respond
• Portions of the Multi-Touch display do not respond
• Multi-Touch display is very slow to respond
• Multi-Touch response is erratic

Resolution

If your device is experiencing any of the symptoms listed above, try the following steps:

1. Restart your device
   • Hold the On/Off button until “slide to power off” appears. Slide to power off your device. When it is off, press the On/Off button to turn it back on.
   • If you can’t restart your device, reset it by pressing and holding the Sleep/Wake button and the Home button at the same time for a least ten seconds, until the Apple logo appears.
2. Clean the screen with a soft, slightly damp, lint-free cloth.
3. Avoid using the device while wearing gloves, with wet hands, or immediately after applying hand lotion.
4. If you have a protective case, or if you are using a plastic sheet or film on the display, try removing them and testing the device without it.

Additional Information

Tip: To isolate an issue related to a portion of the Multi-Touch display, follow these steps:

• Open the Maps application and double-tap each corner, then the center, to verify that it zooms in to each section.
• If a specific area is affected in another application, note the location and try to verify touch functionality for that location in the Maps application.

Possible cause:

• Sensor B62 damaged
• Cable B62 damaged / wire break
• Relay K33 damaged
• Contacts 51 / 52 on contactor K1 damaged

Possible cause:

• Wrong weld power limiter settings.
• Tooling sensor B6 (sensor inside calibration crown) not adjusted well. Distance to can body to big.
• Adapter cable between tooling sensor B6 and cable to control damaged / wire break.
• Cable between adapter cable and control unit damaged / wire break.
• Clamp nr.3 or clamp nr.5 on pacemaker electronic board not fixed well.
• Welding pressure adjusted to low and pressure switch S31 do switch off current.
• Upgrade over voltage protection for welding pressure switch not installed (Varistor on supply of S31). Voltage peak on 24Vdc can create short dropouts of S31.
• Welding pressure switch S31 damaged.
• Contact on welding pressure relay K19 damaged / in bad condition.
• Contact on welding current on contactor K13 damaged / in bad condition.

Problem:

The waterflow LED is on during start up of production / The waterflow LED do switch off only if the button “production on” is pushed for a long time.

Possible cause:

• Waterfilter dirty
• Flowswitch dirty or damaged
• Waterpressure switch dirty or damaged
• To low water pressure => check the cooling unit / the filter on the cooling unit

Possible causes:

• T-Z-bar broken
• Z-bar cooling insufficient (if not existing on your welder, ask us for a upgrade kit)
• Welding frequency too high (ask us for a Pacemaker upgrade: change from triangle to sine wave welding)
• Not enough cooling water (check proper adjustment of water flow switches)
• Cooling water too warm

Possible cause:

The encoder signal for the production speed of the inverter U7 is coming from a external encoder mounted on the downstacker. On the shaft of this encoder there is a small white plastic gear wheel mounted. Please check the screw of this wheel, it might not be fixed well.

> See picture below to find the encoder.

This is the result of a wrong flexer setting!

Possible cause:

• U1 inverter feeder motor reach the adjusted current limit because sheet stack falls down/feeder crash. Remove sheet stack and check the mechanical adjustment of blank magazine and feeder.
• U1 inverter current limit is set too low. Can be adjusted with parameter C022. Attention! Before you increase that limit check if the feeder can be turned by hand easily and mechanical condition is perfect.
• For reset inverter switch off and on the machine.

Copper wire change from 1.38 to 1.24:

1. Before you change to the smaller copper wire, measure the wire elongation, main welding current and welding pressure and make a note.
2. Make sure that the burrs on the tin-plates are well, try to minimize (damage of copper wire!).
3. Leave both pressures on the air regulators (wire tension) as they are. 1.8 bar for the profiling unit, and 3 bar for the wire chopper.
4. A new groove profile for welding rollers are necessary:
   Width 1.80mm, depth 0.30mm. We offer the correct regrooving tool!
5. Profile of copper wire: 1.75 +0.02/ -0.02
6. Reduce the distance (gap) between the transport rings of the wire chopper from 0.35 to 0.25mm.
7. Check and adjust the nosepiece height with the delivered carbide gauge plate (in the black tool box)
8. Measure the wire elongation after change to 1.24mm copper wire, main welding current, welding pressure and compare with results before! Wire elongation might be slightly greater, but within 2%, no problem.

Please check following points on your CM16 welder:

• Adjust the tooling with the mandrel. All precalibration rollers have to touch the mandrel slightly.
• The center of the calibrating crown (diabolo roller) has to be between 1.0 to 2.0mm behind the center of the lower welding roller! Please measure carefully.
• Check the angularity of all 3 axes of the main calibrating tool plate.
• Check the height of the front carbide Z-bar (nose- / headpiece). If it is too deep, then it could cause a different overlap.
• Check the cutting tolerances of the tin plates according our specifications on our webpage.
• Adjust the welding pressure on the precise air regulator to 2.8 – 3.0 bar.
• Check the wire gap within 5 – 10 canbodies: The tolerance should not be higher then 1mm.
• Control the tin layer on the upper and lower copper wire, it has to be in the center.
• Rollforming has to be parallel, and the blank edges has to be around 5mm overbended.
• Check the overtravel according the rule on the carriage.
• Check whether the idler wheel in front of the lower welding roll is in correct position, or whether the circlip is missing (X-plane only)!

Click here

1. Welding speed set too low. Cans are hitting other cans (tin mould?)
   • Remedy:
     • Recalculate correct speed (see manual CM16 / chapter 6.6). Set welding speed 2-3 m/min higher than calculated. If this then works get in touch with CANMAN.
2. The guide tool is set too narrow.
   • Remedies:
     • Reset guide tool using the calibration arbor.
     • Check cuts.
3. Upper inner transportation finger is brushing against the catch rail plate.
4. Insert brace is brushing against the catch and guide channels.
5. Synchronisation is not correct (see manual CM16 / chapter 7).
6. Re-adjust the safety clutch slightly – ATTENTION: max. 10% higher!
   If the clutch is already adjusted beyond 100%, then it may possibly no
   longer engage correctly and is faulty (contact CM).
7. Switch off the machine completely and turn the crank by hand. There must be no increased resistance at any point.
   • Remedies:
     • Lubrication
     • Loosen belt and turn once more (possibly a problem with the motor).
     • Dismantle the whole unit
     • Replace running roller
     • Replace shaft bearings

Possible cause:

• With the spring loaded welding pressure system, the upper welding roll should be pushed down by the air pressure cylinder.  When the welding rollers are closed, the cylinder should be released and should not additionally pushing the spring. Because then the welding pressure will be too high.

Corretive:

• Doublecheck the cylinder settings for the lift-up and the drop-down position of the welding roll. Adjust the setting, there might be a loose setting screw!

Cause:

• Check the clearance between bending wedge and upper rollformer shaft. The clearance might be bigger than 0.10 mm!

Corrective:

• Undo on each side the two M5 (black flat head) screws, and turn the whole bending wedge support left and right, until you reach on both side the needed clearance. Lock the screws and double check the clearance with the feeler gauge. 0.05 is too small and 0.15 mm is too big, depending on the thickness range of tin plates of course.

Possible cause:

1. Check the water filters:
   When Power ROLL is in use, there is a 50µm filter cartridge in a white body, normally placed on the delivered chiller.
   See also in the manual (chapter 7) how often the filter should be exchanged, and after what time the emulsion has to be exchanged!When mercury rollers are in use, there is a little 250µm filter mounted in the inlet of the water station. Open the filter and blow off the insert til the meshwork is clean.
2. The water pressure on the water station must show minimum 5.0 bar!
3. The flow meter of the lower welding roller must show minimum 5.0 l/min!
4. Take off the water tube in the outlet of that cooling circuit, and measure how many liters emulsion/water is coming out per minute.  Compare that value with the adjusted value on the flow meter. The value of the water flow should be around 1 liter higher than the flow meter, or the flow meter should stay at least at 5 l/min.
5. If less than 5 liters is coming out, do the following:
   Take off the X-Plane welding roller support completely, and check whether both round connections (center of rotation) between arm and X-Plane are correct positioned! If they are turned, means positioned wrong, they may reduce/close the water circulation between arm and welding roller!Put the X-Plane and welding roller back, and blow out the whole circuit by compressed air.Take off the water tube in the outlet of that cooling circuit, and measure how many liters emulsion/water is coming out per minute. Now the welding arm and roller should remain chilly again.
6. Adjust now the flow meter to 5.0 l/min and start the production. If everything is correct, the production will not be stopped.
7. Adjust now the flow meter to the max, means completely to the top, and try to start the production. There should occur an error message on the touch screen, showing that this cooling circuit has not enough water, and production can not being started.

NOTE: Only applicable for CMX8 with serial number until No.182 (with Linmot controller type E 1130 and E 2030)

Possible cause:

• Cable break in motor cable or extension cable.
  • replace extension cable or replace motor with fixed cable.
    NOTE: Maintain minimum bending radius of 25mm for the cable!

Possible Causes & Resolutions:

• No supply of a slave on the bus system.
  • Check supply of all slaves.
• Address of slave on Profibus is wrongly adjusted.
  • Check the linmot controller. The correct setting you can find on the wiring diagram.
• Wrong position of the switch for end resistant on the bus plug.
  • Check all switches on the complete bus system. Follow the cable seriously from PLC to last slave. First plug and plug of last slave must be set to ON, all other plugs to OFF.
• Pacemaker™ settings lost because of empty ram battery
  • Replace battery. You can find more information here => Pacemaker – Support (canman.ch)
  • If the ram battery of the Pacemaker is empty and the settings are lost, the profibus communication may no longer start and also the analogue outputs, which control the speed for the wire drive and downstacker, are switched off (0Vdc).
  • After a battery change, the Pacemaker™ may have to be rebooted 3 – 4 times. To do this, disconnect Pacemaker™ from the mains and reconnect it (fuse breaker Q5 off and on again). Check the parameter settings before start the welding machine. If you have no access please open a ticket to get support => Can Man Support

Checklist:

• Set the roll clearance to 30-50% of the sheet thickness.
  • refer to the manual.
• Do you have red springs in use for the upper front roll?
  • reduce the spring tension and check the spring color.
• Spring pressure too low:
  • Tension the red/black springs with 3 – 3.5 revolutions.
  • Check the roll clearance with a dial indicator.
• Rollformer motor too weak?
  • Provide us with the nameplate and a photo of the motor.

• Change the frequency inverter of the rollformer motor to 87Hz technique.
  • This is the new standard of the CM X8.
• Do you have a two-piece catching plate around the lower welding arm (Rollformer 420/540)?
  • This helps to guide overrounded canbodies back into the Z-rail.
• Have you mounted a inner mandrel in the canal (Rollformer 420/540)
  • This also helps to guide overrounded canbodies back into the Z-rail.
• Catching canal: Is the interior measurement of the two shells corresponding to each other?
  • If the interior diameter is too big, too open-rounded canbodies might not be correctly conducted into the canal.
• Catching canal:
  Does the canal flap works properly?
  • The flap might even touch the canbody, which is being welded. Only the a perfect adjusted flap fulfills their purpose.

• Check the upper rollformer plate: Use a dial indicator to see, if there are back and forth or up and down movements.

Possible cause:

• Problem with the touch panel data file, which is loaded on the memory card.
  • Exchange the memory card. Before CanMan will send you a new card, we will store your parameter (prior shipment of your X8).
• The touch panel itself has a fault.
  • Exchange the touch panel.

NOTE: all timing settings are stored on the PLC and not on the memory card.

Possible Cause (CM16 / S, X8):

1. Take off the crown and mount the setting mandrel.
   If the mandrel does not fit, first move the accordant diabolo rollers a bit out of the crown center!
2. Adjust now the top 2 diabolo rollers first.
3. Reset the top diabolo roller first. Only the center of the diabolo roller must touch the mandrel!
4. Now reset the other diabolo rollers. Only the center of the diabolo roller must touch the mandrel!
5. Take care, that the clearance between all diabolo roller ends are equal.
6. Make sure that the gap between both roller ends is as small as possible, with other words, move them towards the “welding center”.
7. Make sure that all spring tensioned pre-calibration rollers are touching the mandrel and have a preload of about 0.2 – 0.5 mm!
   no gauge available except operators sense.
8. The top pre-calibration rollers shall touch the mandrel or have a clearance of max. 0.5 mm!
9. After you mounted the calibration crown back into the welder, make sure that the level of the crown is parallel to the bottom plate. Measure the distance left and right with a rule, and set the height left and right within 1 mm.

Read also this checklist here.

1. Clean the surface with a moist cloth. Check also for scratches or damages.
2. Check if the frame presses on the touchscreen. The active surface is bigger than the screen. If necessary bring some clearance  between the frame and the touch.
3. If you tip simultaneously on two spots, the touchscreen can block for a short period. Wait for a couple of seconds.

Download PDF here

This might be possible, because the triggering is inverse (this means with a minimal distance to the sensor, it results a max. frequency.

• Check the distance of the analog sensor (description).
• If this doesn’t help, place the programming display on the converter U6 and change the parameter C26 from –50% to –55%.

Possible cause:

1. Machine control is not „ON“
   (help: key „wire drive manual“ is shown dashed in the display)
2. The analog sensors (B1 & B2) are not properly adjusted. See the following description.
3. Pendulum head turns, but the copper wire has slippage:
   • increase the wire tension for the chopper unit by 0.2 bar (min. 2.0 – max. 2.5bar)
   • groove worn out, recess the welding disc.
4.  Converter U4 defect.

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.

Corretive:

• Replace water filter or increase water inlet pressure (min. 5 bar at the inlet).
• Check / adjust water pressure switch; see picture below: manometer (1) / pressure switch (2).

WARNING: Do not adjust pressure switch unless synchronized / confirmed with / from Can Man!

Corretive:

• Delay off time drives has to be increased (access over spanner symbol, key symbol, customer password, key symbol, time settings, drives off delay).
• Check the overlap in the end, maybe overlap is too small, and it looks like not welded.
• Also possible: time “jam in weld section” (longest canbody?) did stop the welder, error message should appear in the touch screen!
  contact Can Man.

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.

Report all steps, new or different settings, and old and new production parameters (can size, cpm, weld speed, weld current, weld frequency, current wave-form and transformer step) for an easier overview and follow-up ! (www.canman.ch /Open new ticket and add your document)

Note on which tin-plate parameters (thickness, hardness, tin coating inside / outside, rolling direction, BA or CA, supplier, printed or not) such faults occur, and on which tin-plates not !

Basic parameters & settings to be checked first

1. Tin-plates must be cutted within the allowed tolerances:
   • Measure the tin-plates and report if out of tolerance!
   • Follow sheet „blank-cutting tolerances“! (www.canman.ch/SUPPORT/Canmaking/002)
   • Are all tin-plate parameter clear and noted: Thickness, hardness, tin coating in- and outside, rolling direction, BA or CA, supplier, printed or not
2. Can-bodies must be correctly rollformed:
   • Not conical and best roundness must be reached!
   • Overlap of both tin-plates edges:
     • ø 52 ~ 5 mm
     • ø 99 ~ 15 mm
     • ø 153 ~ 30 mm
     • ø 284 ~ 60 mm
3. The copper wire must be correctly profiled and the surface not damaged:
   • The width of the profiled copper wire shall always be 0.05 mm smaller than the profile-groove in the weld rollers!
   • Measure the width of the profiled copper wire within around half a meter on several position, and note the variations. Maximum difference of 0.05 mm is allowed. If you measure more, check the concentricity of the profiling rings.
   • Change the copper wire profiling rings or idler/guide wheels if the surface of the copper wire shows a damage.
4. Both weld rolls must be regrooved after its regular groove life-span:
   • To avoid unexpected heavy weld faults, it is recommended to implement the total piece-counter and the regrooving interval into the production order!
   • As an example:
     • Upper weld disc ø 90 mm to be regrooved after 3 mio cans (interval depends on, type of welder, type of weld roll and welding speed).
     • Lower weld roll ø 62 mm to be regrooved after 2 mio cans.
     • Example: Total piece counter at production start at 28 mio welded can bodies, upper weld disc has been regrooved at 25 mio, therefore to be regrooved now! Lower weld roll regrooved at 27.5 mio, therefore to be regrooved at 29.5 mio.
   • After every regrooving, weld roll and / or z-bar must be repositioned: Use the correct tools to reset the lower weld roll and/or nose-piece, and the upper welding roller!
5. The z-bar must be clean in and outside – and not worn -, calibration crown must be clean, and all pre-calibration rollers shall turn easily:
   • A dirty z-bar may not be well insulated, therefore the risk of wear is higher and the weld current is flowing over z-bar and tin-plate to the weld center!
   • Note: The insulation of the secondary circuit should be controlled yearly!
   • Non-turning pre-calibration rollers can create body-offset and inconstant can gap!
6. The calibration crown center must be correctly positioned to the weld center:
   • The center of the crown must stay between 3 – 0.5 mm before the center of the lower weld roll (in weld direction seen).
7. The position and speed of the exit conveyor (all conveyors which transport the can body out of the weld center) must be aligned perfectly.
   • Both belts of any V-Shape conveyor need to have a gap of 0.3 – 0.5 mm to the can body. If available use a setting mandrel instead of a can body. The alignment of the conveyor must be absolutely parallel to the weld direction!
   • The gap between two can bodies on the exit conveyor should not be higher than10 – 20 mm! (if can gap is 1.0 – 3.0; see „can gap“ in point 12.)
   • A driven diabolo roller / bottom conveyor after the diabolo rollers must run the same speed like the copper wire!
8. Both tin-layers must be centered and parallel to the copper wire:
   • That means that all mechanical settings are correct!
9. The copper wire tension and elongation must be correct:
   • Make sure that the air-pressures for the pneumatical cylinders are set correctly, or the copper wire is in the right groove of the wire drive disc (Soudronic m/c’s only).
   • Measure the copper wire elongation after the lower weld roll, or after the weld roll before the wire chopper: Elongation varies under normal conditions between 0 – 4 % of the can body height.
   • A sufficient copper wire tension is important to avoid a slipping copper wire on the weld rolls!
10. The can body overtravel must fit:
    • Set the overtravel according manual / scale on the transport carriage!
    • Measure how many mm the can body will be pushed over the center of the weld rolls.
11. The welding pressure must be set correctly:
    • Welding pressure for Wima welders vary between 35 and 50 kg / daN. Start with ~ 45 kg / daN (if needed check the manual to convert in bar).
    • 50 Hz Wima welders using welding pressure between 35 – 50 kg/daN as well.
12. The welded overlap must be correct, and on beginning and end within allowed tolerances:
    • Correct welded overlap depending on z-bar:
      • Z-bar of 0.3 mm results in a welded overlap of 0.4 – 0.5 mm
      • Z-bar of 0.4 mm results in a welded overlap of 0.5 – 0.6 mm
      • Z-bar of 0.6 mm results in a welded overlap of 0.6 – 0.7 mm
      • Z-bar of 0.8 mm results in a welded overlap of 0.8 – 0.9 mm
    • If the overlap is not correct, adjust until overlap is correct:
      • Reset the calibration crown if needed with the mandrel. The diabolo-rollers should not have any radial-play!
      • Adjust the overlap according manual.
    • Once the overlap has been set, double check and set the can gap. Increasing the overlap will reduce the can gap, decreasing the overlap will increase the can gap.
    • Weld around 5 cans and measure the gap between the tin-layers. A good can gap measures between 1.0 – 3.0 mm (depending on the can body format). Any variation should be within 0 – 1.0 mm.
13. The weld current frequency must fit:
    • Welders with a static frequency inverter should have a welding spot length between 0.6 – 1.2 mm.
    • A welder without static frequency inverter should be operated between 8 – 12 m/min. Reducing the welding speed does decrease the welding spot length.
    • The welding spot length should always be as long as possible (by reducing the frequency) to reduce energy and heat in the welding seam and in the welder to a minimum.
    • Main target must be a flexible and smooth welding seam!
14. The main weld current must be set correctly!
    • How to do:
      • Reduce weld current until cold weld zones appear. Tear-off test must be done at an angle of 30 – 45°, means try to pull-off the top tin plate edge. To be done from each side. Note the weld current value!
      • Increase weld current until hot weld appears. Tear-off test must be done at an angle of 0°, means pull-off the seam only and find out when the seam starts to become fragile. Note the weld current value!
      • Add 2/3 of the weld current difference between cold and hot weld seam to the cold weld seam value, and start the production!
    • Set beginning and end time and beginning and end current!
    • Note: If the welder is running with triangle wave-form, make sure the duty-cycle is between 80 – 90 %. If the welder is running with sine wave-form, make sure the right transformer step has been choosen! Contact us if you are not sure.
15. The seam-extrusion inside and outside must be equal!
    • If the seam extrusion is bigger inside, reduce the height of the calibration crown. If the seam extrusion is bigger outside, increase the height of the calibration crown.

Checklist to Avoid Micro Leaks

Micro leaks can occur within the seam and beside the seam – especially on cold-formed areas like necking, beading, flanging or seaming -, even if all above mentioned basic parameters & settings seems to be correct.

Micro leaks can have various sources: Wrong settings on the welder, tin-plate parameters which support such faults, worn or wrong machineries in the downline, or tin-plate parameters which do not fit to beader, necker, flanger and seamer.

For a better visual understanding put the faulty-can bodies in a water bath, and inspect the leaking area by a microscope. Store the pictures if possible!

1. Make sure that necker, flanger, beader and seamer are in good condition, and do not stress the weld seam more than needed.
   • For further information check the manuals (check the tin-plate specifications range) or contact the supplier!
2. Try to weld different tin-plates to understand which tin-plate parameter can be produced without such faults.
   • Rolling-direction parallel to weld seam can increase the occurrence of micro-leaks!
3. Micro-leaks in and near the seam can be reduced by changing the energy in each welding spot:
   • Reduce the welding frequency within the possible range (see point 13. in above checklist), and set the main weld current again (see point 14. in above checklist). The production cycle (cpm) must probably be reduced to reach a good weld seam. Produce a certain number of cans and test them.
   • Increase the welding frequency within the possible range, and set the current again. Produce a certain number of cans and test them.
   • Reduce the welding pressure to max 45 kg / daN, and set the main weld current again (see point 14. in above checklist). Produce a certain number of cans and test them.
   • Reduce the welded overlap by around 0.10 mm, and set the main weld current (see point 14. in above checklist). Produce a certain number of cans and test them.

Checklist to Avoid Flange-Cracks

Flange cracks can occur at the beginning and the end of the seam, even if all above mentioned basic parameters & settings seems to be correct.

Flange cracks can have various sources: Wrong settings on the welder, tin-plate parameters – for instant parallel rolling direction – which support such faults, worn or wrong flanger in the downline, or tin-plate parameters which do not fit to the flanger and or seamer.

For a better visual understanding put the faulty-can bodies in a water bath, and inspect the leaking area by a microscope. Store the pictures if possible!

1. Make sure that flanger and seamer are in good condition, and do not stress the weld seam more than needed:
   • For further information check the manuals (check the tin-plate specifications range) or contact the supplier!
2. Try to weld different tin-plates to understand which tin-plate parameter can be produced without such faults:
   • Rolling-direction parallel to weld seam will increase flange cracks, because the seam cracks in line with the rolling direction!
   • Weld tin-plates with cross rolling direction and test them.
3. Flange cracks can be reduced by changing the energy in each welding spot:
   • Reduce the welding frequency within the possible range (see point 13. in above checklist), and set the main weld current again (see point 14. in above checklist). The production cycle (cpm) must probably be reduced to reach a good weld seam. Produce a certain number of cans and test them.
   • Increase the welding frequency within the possible range, and set the current again. Produce a certain number of cans and test them.
   • Reduce the welding pressure to max 45 kg / daN, and set the main weld current again (see point 14. in above checklist). Produce a certain number of cans and test them.
   • Reduce the welded overlap by around 0.10 mm, and set the main weld current (see point 14. in above checklist). Produce a certain number of cans and test them.
   • Activate the current reduction on the begin and end to reduce the heat in the first few welding spots.
4. If above listed does not help, some theoretically wrong settings could help:
   • Increase the can gap to have completely different welded begin and end. Produce a certain number of cans and test them, and set back if it didn’t help!
   • Set a slight can-body offset, to bring the current different into the tin-plate. Produce a certain number of cans and test them, and set back if it didn’t help!

Download PDF here

Possible cause:

• Maintain the calibration crown according to the manual (Book 2; chapter 5.5.4.)
  Important: All precalibration rollers must turn smoothly, not one should be blocked.
• Reset the calibration crown according Resetting of the tooling
• Guideline: The higher the production speed, the more difficult to control body offset issues!
• Tin deposit on z-bar grooves
• Rollforming not enough

Special settings:

• The setting of the first, second and probably third spring tensioned rollers before the diabolo roller crown may vary in setting.
• Basic setting – first, second and – depend on can height – also third rollers should have 0.10 mm movement.
• If the body offset still remain, start to undo all the nuts of the first pre-calibration rollers by a sixth turn, and so on.
• Check whether the Z-bar grooves are clean or full of tin/steel pick up:
  • If the grooves are full, clean them by sandpaper 400 or higher. For better cleaning take off the lower welding arm completely. Switch off the chiller before start to dismantle!
  • Check the insulation according manual – How to do an insulation check (yearly task)?
  • Check whether the secondary circuit – lower arm side – is connected to ground by a separate green/yellow cable!

Download PDF here

Download PDF here

Possible cause:

• The setting of the magazine is wrong
• The separating air is not correctly set, or the air pressure is too low
• Too much tin plates – especially on can heights over 200 mm:
  • in the magazine, the weight is too high!
• Tin plates have too much burrs
• Suckers are worn
• Sucker height too low
• Linmot slider is not well positioned:
  • Pusher plate must stay around 2 mm behind the tin plates
• No signal of tool sensor B6:
  • Maybe gap between can body and sensor to big?
  • Maybe wire break and no signal on plc/pacemaker. Check cable and plug!

1. Try to move the tension cylinder / cylinders by hand back and forward, without air pressure and wire.
2. Try to turn lower welding roll (without wire) by hand.
3. Check the groove of the upper welding disc.
4. Is the wire width correct?
5. Adjust the pressure of the tension cylinders: Cylinder below wire profiling unit requires 1.6 bar. Cylinder (behind main alu-plate) for wire chopper unit requires 2.0 – 2.4 bar.

• Take off the upper rollformer shaft / bending wedge unit completely. Release first both spring pressures completely!
• Change the bending wedge, take care that the roller is not falling by mistake onto carbide wedge! Put a rag between.
• Change the support bearings below lower rollformer roller first if damaged!
  • Important: Left and right of both bearings a shim of ø 8/14 x 0.5 mm is needed, to avoid that outside rings of bearings are touching lateraly on the hardened support and becoming hot!
• Control whether the little shaft (into the needle bearings of lower rollformer shaft) in the right side plate is really fixed well or not.

• Mount the lower rollformer roller completely, and measure the clearance between roller and bearing: 0.02 – 0.05 mm.
  • Important: If no clearance can be measured, take off the hardened support with bearings, and grind the lower side slighty until above mentioned clearance 0.02 – 0.05 mm has been reached.
• Mount the upper rollformer shaft / bending wedge unit back (use only bores in the middle!), and move the bending wedge about two turns up. Avoid that the wedge touches the lower shaft after closing the rollformer! Don’t tighten spring pressure yet!
• Close the rollformer, and hold left and right a feeler gauge 0.10 mm between both rollers. Close the rollformer slowly step by step. Take care that bending wedge will not touch lower roller!
• Reset the height of upper roller until you can move out both feeler gauges easily. Now open rollformer and measure the clearance between bending wedge and roller. It should min. 0.3 mm.
• Double check ones more whether a proper clearance between lower roller and bending wedge is there.
• Close the rollformer completely and reset spring pressure and set roller clearance correctly.
• Now the rollformer is ready for first rollforming trials.

The damaged/bended corner is touching first the inner catch rail.

The inner catch rail looks like a hook and will be found underneath the lower rollformer shaft on the catch station.

By changing the horizontal level of the catch channel slightly, the roll-forming direction of the tin plate will be changed/affected, and the whole tin plate edge should touch the catch rail equally.

1. Measure the inner left and right distance between the hard-chromed guidance channel and internal hard-chromed guide-shell (around lower rollformer shaft). The left/right measures are most probably not equal.
2. Try to correct one of the distance until both measures are equal. If you are not sure how to correct, feel free to contact us via the online support system.

The error occures when there is a problem with the measurement of the wire speed (not wire speed by self).

• Check the gap between idler wheel and sensor, 1mm is recommended!
• Check the bearings of the idler wheel! Is turning smoothly? To much play can create an unstable gap to the sensor.
• Check cable between sensor and plc!

If there is still a problem with the measurement of wire speed, you can proceed as follows to restart production:

1. Push the “Key button” on home screen
2. Login with your password ****
3. Push again the “Key button” to reach the setting window
4. There you can find a second “Key button”. Push that button to reach the main setting window.
5. There you can find on right top position a button “Wire speed control”
6. Switch this funktion to ”OFF”

Please note: The workaround described above is not recommended for permanent production!

• 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!

P03 = positioning countering error

Possible causes:

• Resolver on the backside of the bodytransport motor is damaged.
  • Check if the bearings are worn out!
• Resolver is not fixed well on the shaft.
  • Fix it!
• Wire break in the cable between resolver and servo controller.
  • Check the cable!

Possible cause:

• Bad insulation of the G-sensor to the bracket. This can cause errors to the PM board.
  • Open the housing of the bracket and insulate the G-sensor properly.
  • see also Pacemaker FAQ “PM send error” / “PM receive error” or welding parameter don’t match after starting the machine.

Possible cause/checklist:

1. Position Linmot pusher plate:
   Must be 1 mm behind tin plate edge!
2. Adjust roller clearance on all 7 pairs according manual.
3. First roller pair:
   If you can’t get 0.1 mm roll clearance, check the toothed gears inside/outside. They may have a wrong lateral position; that ends in a too big clearance between the shafts!
4. Test after setting:
   Take off main and inner timing belt, rollers touching each other, all gears must have slight play!
5. Check and adjust a well rollformed canbody:
   Form of canbody must be round, both edges must have a parallel overlap, depending on the diameter!
   – Diameter 52 mm = approx. 5 mm
   – Diameter 99 mm = approx. 20 mm
6. Check the feeder angle and rollformer speed according the recipe of the canbody you are currently running.
   NOTE: «If parameter is different from recipe, it has been changed without authorization of Can Man! Any guarantee claims will be refused!»
7. Check the curve you have in the tuning window with the recipe of the canbody you are currently running.
   NOTE: «If parameter is different from recipe, it has been changed without authorization of Can Man! Any guarantee claims will be refused!»
   
8. Make sure you have mounted the correct pair of final pusher fingers (see the diameter range engraved on the fingers).
9. Check the actual overtravel with the help of the manual.

The recipe helps to adapt the speed of the incoming can into welding roller and the actual welding speed. In the best case, those speeds are equal.

Below you find a table of this recipe in steps of 10 mm can height.

Possible cause:

This problem occurs, if the main switch of machine is turned on, but the machine is not running production for a longer period. The cooling plate of servo drive is heating up, because the water valve is turned off during this time, to prevent condensation water.

Turn off the main switch, if you don’t run the machine for a longer time.
To get rid off the error with overtemp. servo drives you can go to the „Tuning page“. Press the button to switch on the main valve for the cooling system manually. Keep this button pressed for a few minutes, the system will cool down and you can start the machine normally. If you close the “Tuning page”, the main valve is switching back to automatic mode, controlled by „Production ON/OFF“.

Possible cause:

• Drives for the height change magazin and infeed system are active and stopped before reaching the position – overcurrent active.
  • Go to the mask for height change, push the reset button and the start button. The drives must reach the position without overcurrent message. If the error comes again, check the free movement of mechanical system.
• If “SF” and “BF” on the PLC are “Red”, some drives on profibus are missing (no connection of height change position drive to profibus).
  • Check Fuse F6/F7!
  • End resistant of all profibus plugs must be “OFF”, only first and last plug “ON”.
  • Open the profibus plug on height change positioning drives, then open and close again the connectors!
  • Check the profibus cables!
  • Check the profibus module for damages or bad contacts!

Possible cause:

• Check the wire groove, maybe the profil is not straight anymore (see also if short near the seam).
• Too much welding current.
• Too low welding frequency.
• Check the tension the belt for the profiling unit and pendulum rollerhead.
• Servo drive transport belt: Check if the whole transport belt  unit is vibrating during positioning. If yes: Change the drive gear on top the servo motor.

Possible cause:

• Since the slider of the linear motor contains strong magnets, remove dust or small particles from slider with a disposable paper.
• Make sure that you have a clearance of 0.1 – 0.2 mm between the pusher plate and the vacuum plate.

Possible cause:

1. Take out the bottom gear inside.
2. Take out both gears outside (motor side).
3. Adjust the inlet shaft clearance 0.10 mm.
4. Mount both gears outside again.
5. Move the upper gear outside laterally, till you feel a play between the teeth of both gears!
6. Don’t mount the bottom gear inside anymore, you don’t need it!
7. Lubricate the gears outside with a special gear lubricant (can be ordered from Can Man / article No. 006950).

Possible cause:

• Check the air pressure on the small air regulator, the value must be around 0.5bar (pressure to engage the clutch).
  • refer also to the touch screen “Air” symbol, where you find the exact values.
• Check the air pressure on the precision air regulator, left side from synchrostar motor, to 1.6 to 2.0 bar (pressure to disengage the clutch)
  • refer again to the touch screen “Air” symbol.
• Check whether the safety clutch is engaged or not: Turn the synchrostar by hand, and see whether the motor is also turning or not. If yes, the clutch is engaged!
• If the clutch is engaged, but the error message still remains, the sensor B69 might wrong positioned:
  • Check if the LED from the sensor is OFF.
  • If the LED is still ON, turn the sensor a quarter turn counterclockwise, or until the LED is OFF. Do not turn the sensor too much counterclockwise. If the distance is too big the clutch does not stop the machine in case of a crash. To test you can adjust the precision air regulator of clutch to „0“. Now the clutch is disengaged and the sensor has to be ON.
  • Make sure that the sensor has still a clearance of about 0.5mm refer to manual Mayr EAS 450  or Mayr Clutch 0-481-325
  • Turn the synchrostar and make sure that there is no resistance coming from the sensor/clutch!

Possible cause /checklist:

• Check all terminals at the Pacemaker board.
  • wait for 5 minutes after switching off the unit).
• Check the welding pressure: Display > 35 daN!
• Are the time settings t1 and t2 correct?
• Is the weld power limiter switched „ON“? Which mode is chosen? Glueing?

Possible causes:

1. Both supporting bearing underneath lower rollformer roller are broken.
   Take off the roller, and check each bearing, if needed exchange them with new ones.
2. The shaft clearance and/or pressure of the last rollformer roller pair (bending station) is not correct.

How to reset:

• Open the rollformer completely, close and lock it
• Check whether the lifting motor has enough play after the rollformer is locked or not.
  • If not, the motor may have a wrong internal micro switch setting.
• Make sure the rollformer is locked.
• Completely unload the springs on both sides till each spring has an axial play.
• To ensure that the roller is easily moving up and down, lift up each end of the roller by hand.
  • Belt tension inside does not effect conical rollforming!
• Reset roller clearance to 0.1mm by feeler gauge.
  • Check the clearance with two gauges on the very left, and on the very right end of the roller!
• Turn both springs clockwise till each screw touches the spring.
• Load each spring by 2.5 revolutions.
• Reset roller clearance to 0.05 – 0.10 mm
  • Check with two gauges on the very left, as well as the very right end of the shaft. After that you should be able to get a proper rollformed body, with an overlap of 5 mm.

The position of the welding roll (WR) has an influence on the overlap at the beginning and at the end.

If you still couldn’t resolve the problem, read more at: I have problems to keep a constant overlap

Possible causes:

• The movement (the back and forth) of the wire and the final wire break happens, because the analog signal is right on the threshold to start. You can solve the problem, when you increase the „Hertz“ setting of the frequency converters U4 and U6.
  • Place the programming display on the converter U4 and change the parameter C19 from 5Hz to 7Hz, and do the same for the converter U6.
• A second reason for this phenomena could be the incorrect position of the analog sensors B1 and B2, see the following description, which is explained for the CM X8, but is valid also for the other automatic welders.

Possible causes:

• The timing of the rounding process is too late.
• The rolled can body is clamped or caulked in the catch station.
• One or more transport fingers is / are twisted or lost.
• The tension of one or both transport finger timing belts is too low.
• Check the transport finger’s offset.
• The final pusher fingers of the Synchrostar are taking over the can body from the transport fingers too late.
• The precalibration is set too tight, or some precalibration rollers are not easily turning anymore.
• Check if any groove of the z-bar section is worn.

Possible causes/checklist:

1. Take the wire and switch out of the air supply. Can you smoothly move both cylinders of the wire drive?
2. Check all rolls of wire drive system. Turn them by hand. All bearings ok?
3. Check the transport wheel of wire chopper unit, condition and distance (acc. to instruction manual)
4. Remove the belt of the motor for pendulum roller head and turn them by hand. Is it turning smoothly?
5. Check the same on profiling and chopper unit.
6. Now install the belts and tight them correctly.
7. Put in the wire and adjust the air regulator.
   Cylinder wire profiling unit 1.5 bar and cylinder wire chopper unit 2.0 bar.
8. Change the selector switch to “wire manual” and run the wire.
9. Take a look at welding rolls – is wire position correct?
10. Check profiling of copper wire, correct width and constant?
11. Weld a can with current and without current. Wire break?
12. Have you changed the wire? Use the old one to compare.
13. Check the tin mark on the wire. Ok?
14. Don’t forget to lubricate the profiling unit and chopper unit.

Possible causes:

• Tool plug not properly connected.
• Plug wet or humid.
  • Blow out and dry the plug.
• Short-circuit from the diabolo rolls or precalibration to the mounting plate. Due to the temperature sensor cables, which are guided through mounting plate, an error message could be triggered through induction.
  • Dispose the short-circuit and clean the tooling from welding spillings. Use a contact spray.

Find a complete error list together with the interpretation of the error codes

Download PDF here

Possible causes:

• No supply of a slave on the bus system.
  • Check supply of all slaves.
    Emergency stop must be released.
• Address of slave on Profibus is wrongly adjusted.
  • Check setting of all DIP switches on the Lenze bus module and on the Linmot controller.
    You can find the correct setting on the wiring diagram.
• Wrong position of the switch for end resistant on the bus plug.
  • Check all switches on the complete bus system. Seriously follow the cable from PLC to the last slave. First plug and plug of last slave must be set to ON, all other plugs to OFF.