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.

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:

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:

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:

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:
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.

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

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)

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 here

German instruction: page 52 – 55

English instruction:  page 110 – 113

French instruction:  page 172 – 175

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.

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.

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.

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 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.

This is the result of a wrong flexer setting!

Possible Cause (CM16 / S, X8):

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!

• 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:

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 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.