55 Support Entries

Download regrooving datasheet


Download PDF here

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 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 blanc 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

  1. Switch off the main switch Q1 of the machine.
  2. Wait around 10min before you do anything on the wiring of the pacemaker! The capacitors need that time to discharge!!!
  3. Disconnect both welding cables from Pacemaker.
  4. Measure the resistant of both cable to earth. If the value is very low maybe the transformer primary side have short circuit to earth or the cables are damaged and make some contact to earth. If it looks ok (endless or very high resistant) go to point 5.
  5. Take the welding copper wire completely out of welder.
  6. Control that pendulum roller head is lift up. Put a carton or another insulating material between both welding rollers to make sure that you don’t have any contact between the rollers.
  7. Connect an external cable 230VAC (phase and neutral) to the welding cables, which you have removed on pacemaker before. Use for this external supply a 10A fuse breaker to protect the supply in case of a short circuit of welding transformer. (Take a look to picture on point 3)
  8. Before you switch on the external supply check again:
    – Wire removed?
    – Pendelum rollerhead lift up and isolation between welding rollers?
  9. Now switch on the external supply. If the 10A fuse breaker does not trip it is a good sign and it doesn’t look like short circuit of welding transformer.
  10. To control the output of welding transformer you can measure the voltage between the welding rolls (VAC). The measured voltage is depending on the type of welding transformer. If you change the transformer step this value has also to change. Check the output voltage of each step. Don’t worry if you measure only around 5VAC, the output voltage of welding transformer is a low voltage.

Before you change the transformer step switch off first the external supply!!!

Download PDF english

Download PDF chinese

Possible cause:

  • 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

Use a common Ohmmeter, as you can see on the picture.


Measure the resistance between left carbide ring and main aluminum plate.
The measuring result on the Ohmmeter must be endless!


Measure the resistance between left carbide ring and main aluminum plate.
The measuring result on the Ohmmeter must be endless!


Measure between left and right carbide ring. The result on the Ohmmeter must be endless! This step is to ensure the proper insulation of both rear insulation rings around the taper roller bearings!


The picture shows the correct measuring result on the screen of the Ohmmeter for all three test points!

Download PDF here

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.
  • 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.

This is the result of a wrong flexer setting!

Open the rollformer and you undo the screw on the right handside of the “Flexer”.  

Measure with a ruler the actual position of the flexing wedge.

On the other side of the flexer, you can alter the position of flexer with the M8 screw. Choose a lower position for less flexing.

With more flexing the sheet comes out of the flexer station with less prebending.

If you do less flexing, means that the sheet comes out of the flexer station with more prebending.

After adjusting the flexer, you might have to adjust the rounding slighty!
For more information regarding the flexer and rollformer setting check our manual book 2 chapter 5.4.

1 or 2 (sender/receiver) sensors are fitted behind the first pair of rollers to recognize double sheets.


Sensor in the lower part.


A pneumatic cylinder operates the ejection flap.


The double sheets detected by the sensor are diverted into this channel by means of a switch point.


Setting the double sheet sensor

The evaluation unit for the double sheet sensor is located in either the control box (illustration) or in the immediate vicinity of the rollformer, on the feeder side.


To set the sheet thickness, take a single sheet and lay it on the support rails in front of the first roller pair. You can also open the roll- former and lay a sheet into the rear area by hand. Then close the rollformer again.


Now turn the single sheet back and forward in the first roller pair by hand with the help of the belt.


The two green LEDs „Power“ and „Relay“ should now be lit up on the evaluation unit.


If the red LED „Double sheet“ is lit up, you must carry out a correction.


Turn the left-hand screw „Thickness Adjust“ clockwise until the red LED goes out and the green LED „Relay“ lights up. Add 1-2 additional turns in the clockwise direction.


Now carry out the same procedure with two sheets (double sheet).


The red LED „Double sheet“ should now be lit up.


The cylinder should now also be activated. It will be reset again when the sheets are removed.


Do not turn the right-hand screw „Delay adjust“; this is used for the delay of the cylinder stroke.

You will find further details in Book 5 OEM manuals on the CD.

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.

Possible cause:

  • Wrong direction of rotation of the vacuum pump motor (only when machine has been disconnected from the power).
    • change phases
  • Clogged filter of the vacuum pump (or in the vacuum hose / tube).
    • replace it
  • Clogged bores in the sucker cups.
    • clean it
  • Worn sucker cups.
    • change sucker cups
  • Wrong vertical adjustment of the sucker bar.
    • see manual of welder (chapter 5.3) and learn how to adjust sucker bar upper position
  • Badly cutted blanks with lots of burrs.
    • grind / adjust cutters of slitter
  • Clogged vacuum valve.
    • clean it (see here) or replace valve (CM article No. 005925)
  • LED not “ON” when production “ON”.
    • refer to the electrical manual
  • Too tight adjustment of the blank magazine.
    • see manual of welder (chapter 5.3.) and learn how to set blank magazine correctly
  • Worn sucker rod or worn seals/bearing in the vacuum housing.
    • replace it

NOTE: Only applicable for the model X8-350!

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!

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.

Report all steps, new or different settings, 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!

Open a 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 tinplates 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“! Download PDF
    • 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:
      • ø52 ~ 5mm
      • ø99 ~ 15mm
      • ø153 ~ 30mm
      • ø284 ~ 60mm
  3. The copper wire must be correct 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 are 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.
      • 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 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 are all pre-calibration rollers shall turning 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 unconstant can gap!
  6. The calibration crown center must be correct positioned to the weld center:
    • The center of the crown must stay between 3 – 1 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 have to touch the can body similar. The direction of the conveyor must be absolutely parallel to weld direction!
    • The gap between two can bodies on the exit conveyor should not be higher than10 – 20 mm! (if can gap is 1.5 – 3.0; see „can gap“ in point 12.)
    • A driven diabolo roller must run the same speed like the copper wire!
  8. Both tin-layers must be centered and parallel on 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 correct, 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 between 0 – 4% of the can body height.
    • A sufficient copper wire tension is important to avoid a sliping 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 correct:
    • Welding pressure for Wima welders vary between 35 and 50 kg / daN. Start with ~ 45 kg / daN. Check the manual to convert in bars.
    • 50 Hz welder using welding pressures between 35 – 45 kg/daN, while automatic welders running between 40 – 50 kg / daN.
  12. The welded overlap must be correct, and on begin and end within allowed tolerance:
    • Correct welded overlap depending on z-bar:
      • 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 0.7 – 0.8 mm
      • Z-bar of 0.8 mm results in a welded overlap of 0.9 – 1.0 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 1.5 – 3.0 mm. Any variation should be within 0.5 – 1.0 mm.
  13. The weld current frequency must fit:
    • Welders with a static frequeny 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 lenght 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 correct!
    • 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.
    • The shape or roundness of the can-body is not so important as a correct seam-extrusion!
    • The seam extrusion inside depend on the inner weld roll diameter as well: The diameter difference of upper and lower weld roll should be as small as possible.


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 conditon, 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 occurence 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.
  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 helped!
    • 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 helped!


Download print version

  • Empty the water tank. On 2-circuit cooling unit only cold water tank has to be emptied.
  • Blow off one by one each cooling circuit in the welder. This allows to empty each circuit separately. If your welder has a 2-circuit cooling system only the circuit for the lower and upper weld roll has to be emptied.
  • Change the filter cartridge and clean the filter housing inside.
  • Fill the tank with water only, open main valve Y14, and run the system for at least one hour to flush rests of old emulsion out.
  • Empty the water tank again and clean again if necessary.
  • Fill the water tank with water (or distilled water if requested), and mix the PowerRoll™ coolant H1 in with 8 percent.

We recommend following maintenance procedures:

  • Change the filter cartridge monthly.
  • Change the cooling emulsion yearly. Use the PowerRoll™ cooling system cleaner at any time you change the emulsion.
  • Use the PowerRoll™ cooling system decalcer after around 5 years.

Order numbers:

  • PowerRoll™ coolant H1 (food grade), 7 Liter, 011494
  • PowerRoll™ cooling system cleaner H1 (food grade), 10 Liter, 011495
  • PowerRoll™ cooling system decalcer, 25 kg, 011496
  • Filter cartridge 50 µm, 002446

Safety data sheets see below:

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:

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.

Turn the wheel of the synchrostar, that the pusher finger is as close as possible to the welding roll.

Measure now the distance from the top of the pusher finger to the center of the welding roll.

Distance = Can height – Overtravel Example:
Canheight: 122mm Overtravel: 4.8 mm

Distance: 117.2 mm

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.


Maintenance, cleaning and insulation check (can be used in general for any welder)


  •   Recommended to be done when the main Z-bar has to be changed anyway
  •   Time to do: 4 – 8 hours for 1 person
  •   Turn the main switch off, make sure the water cooling unit is also off!
  •   Take off the copper wire completely.
  •   Take off internal side seam tubes or internal oxyde tube.

 Tubes have to be insulated in the area of rollformer, to avoid any contact to the ground.

(In the area of the lower welding arm is a simple insulation not possible).
− Take off the grounding cable from the lower copper plate going to the welding transformer

    (Do not forget to place back after you finish).
− Clean the whole secondary circuit as good as possible by rag and compressed air.
 Blow from rollformer side towards overhead exit conveyor, to protect the bearings in the rollformer.

  •   Take off the lower welding arm.
  •   Dismount the main Z-bar including front nosepiece.
  •   Clean both Z-bars, the Z-bar slot in the arm carefully, without using grinding paper, to avoid increasing theinternal width!
  •   Check internal/external full ceramic cross bars for damages, no need to take them off, if they are ok.
  •   Clean the contact surface between arm and the copper plate going to the welding transformer with grindingpaper 400.
  •   Use a little flat plate and fold the grinding paper around.
  •   Not a must but recommended: Lubricate one of the contact surfaces slightly by copper grease(to avoid humidity in between. If you decide to do, do it on all other contacts)
  •   Check the O-Ring (to be done also on all following ones)

− Mount the Z-bar back into the arm and measure the insulation by Ohm-meter > 10 Mega Ohm!

  •   We recommend to use a special heat compound to guarantee a better heat transfer from the Z-bar to thewater cooled welding arm!
  •   We recommend to use new insulation washers (recommended also on all others).
  •   Check the little yellow full ceramic idler wheel in front of the lower welding roller, make sure screws/nutsare locked, and the circlip is not missing!
  •   Clean also the upper slot in the upper power plate.
  •   Take off the top copper plate between welding transformer and upper power plate (support of the lowerwelding arm). Clean the plate and the brown insulation plate (take care, can easily be broken).
  •   Clean all areas around the upper power plate, especially the area between power plate and copper plategoing to the welding transformer. This area is difficult to reach, when the lower arm is build in.
  •   Clean both areas between upper power plate and the main alumimium plate (devided by two brown

insulation plates).

  •   Clean the area around the big copper plate (going around the shaft of the upper pendulum rollerhead).
  •   Check following insulations (Ohm-meter > 10 Mega Ohm): Each idler wheel to the aluminium plate.

 Check also every bearing. Attention: Most of them have ceramic balls, marked by a red point!

  •   Each body of the copper profiling unit to the aluminium plate.
  •   The body of the big cooling wheel to the aluminium plate.
  •   The twin idler wheels (between rollformer and upper power plate) between itself but also to the aluminiumplate.
  •   Both transport rings, cutting wheel and pressing bearing/ roll of the wire chopper to the aluminium plate(clean up before may be helpful).
  •   The upper power plate to the main aluminium plate.
  •   The front support of the pendulum rollerhead to the aluminium plate.
  •   The welding pressure cylinder to the supporting plate.
  •   The main aluminium plate to the machine frame.
  •   The pendulum rollerhead to the machine frame.
  •   Calibration crown: Clean the calibration crown first.
  •   Each diabolo roller to the main brass plate.
  •   Support of guidance channel/calibration crown:
  •   Take off the whole canbody guidance including the long aluminium supporting plate (T-shape).
  •   Clean the whole area.
  •   Check the insulation between the long steel guide plate and its supports mounted to the frame:Three brown insulation plates underneath the long steel guide plate.
    Two separate brown insulation plates underneath a long steel bar (30/60 x 40 x 400 mm), to be found on the machine frame, in the area below the calibration crown.
  •   Put now back all parts.

 Make sure you are using only stainless steel screws and washers and lubricate the threads again!

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 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 in can height.


Turn the wheel of the synchrostar, so that the pusher finger is as closeto the welding roll as possible .


Now measure the distance from the top of the pusher finger to the center of the welding roll.

Distance = Can height – Overtravel

Can-height: 122 mm, Over-travel: 4.8 mm

Distance: 117.2 mm

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

WR slightly too high = Overlap at the beginning less
WR slightly too low = Overlap at the beginning constant
WR higher = Overlap at the end better
WR lower = Overlap at the end less
WR lower = Overlap at the beginning less




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

Air Maintenance Unit

Aral Vitam XR 46
(Festo – Part No. 12009388 T116)

Vacuum Pump
Mineral Vacuum Pump Oil
Multi Lube 100 – 750212 (Rietschle)

CM Article No. 003634 (5-lt container)

Cooling Unit
Coolant lubricant Zubora 92 F (standard)
CM Article No. 002609 (20-lt container)

PowerRoll™ Coolant H1 (food grade)
CM Article No. 011494 (7-lt container)

CLP 460 Oil
(e.g. Shell Omala 460)
See also data sheet on CD-Rom in Book 5

Central Lubrication Unit
Lithium Complex KP2P-30/EP – DIN 51502
NLGI Class 2 – Application –30 to +150°C

CM Article No. 007857 standard (400g)
CM Article No. 007858 food grade (400g)

Safety Data Sheet Cooling Lubricant
The safety data sheet of cooling lubricant you will find on CD-Rom in Book 5 in file „Cooling unit“


Gearbox Lubricants (PDF)

Zubora 92 F (PDF)

PowerROLL Coolant H1 (PDF)




The center of the calibration crown (tooling) should be X = 2 – 3 mm behind the center of the pendulum roller head.


To adjust the position, tip the „tool out“ symbol.  


Then you have to loosen the two M10 screws on top of the tooling plate.


Then you loosen the M6 counternut (1) below the plate, then you can adjust the position with the M6 screw (2). When you turn clockwise, you will reduce the distance, when you turn counterclockwise you increase the distance between the calibration crown and the pendulum roller head.


Tighten the counternut (1) again and then tip „tool in“ to check the position. 


The correct setting!


An alternative spot to measure the correct distance is below the tooling plate:

X = 82 – 83 mm.

Remote maintenance:
In the electrical cabinet a modem with a remote maintenance adapter is integrated. Therefore you can do small changes over the phone line.


Recommended is an analog phone line with a direct phone number, with no internal connection through a switch board.


Disconnect the phone line, if not in service! The remote maintenance system depends on a very good quality phone network. A bad network will make the service impossible.


There are two possibilities to do maintenance work or updates to the PLC Software.


Remote maintenance:
In the electrical cabinet a modem with a remote maintenance adapter is integrated. Therefore you can do small changes over the phone line.

Recommended is an analog phone line with a direct phone number, with no internal connection through a switch board.

Disconnect the phone line, if not in service! The remote maintenance system depends on a very good quality phone network. A bad network will make the service impossible.


PLC Software Siemens Step 7:

The Siemens PLC is programed by the Siemens PLC Software Step 7TM, the panel (Touchscreen) by WinCC flexibleTM.


The following requirements are necessary to provide this service:
– Notebook with Software Step 7TM and

WinCC flexibleTM from Siemens
– MPI/DP (Profibus) interface
– Technical engineer with the software

knowlegde of Step 7TM + WinCC flexibleTM.


If you change the software without prior consultation of CAN MAN, the works guarantee becomes void.

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.

The instructions below show you how to connect the following signals: a) Line control b) Error powder unit and c) Release powder

Signal: line control


In order to switch off the downline due to an error, the PLC has a prepared input. To use this input, we need a potential-free signal from the downline, which is closed when the line is ready. Use the terminal E5.1 to connect the line control.


As soon as an error occurs, the destacking of the sheets stops and after an adjustable delay the wire-run and the remaining drives. The canbody transport continues to run slowly. This mode plus the flashing of the key „Production ON“ shows the operator the status of the line stop.



Machine begins to produce independently again, respectively after the release of the line control.


This input should be connected the same way as the line control. Here as well we need a potential-free relay contact of the powder unit. But this contact needs to be open, if there is any error. This signal needs to be connected to E126.7.

The production shuts off, if an error occurs. After that the operator needs to switch on the machine.


Signal: Release powder


In order to switch on the powder, we provide a change-over contact. The contact switches as soon as the production or a single can is triggered. In order to provide enough time for the initialization of the powder, the destacking is delayed by an adjustable time. Before you connect this signal, you have to remove the comb bridge (1) and the link (2), in order to make the contact potential-free.


Use the terminal K6.2 (A124.2).


Consult the electrical scheme of your welder to double-check the various input signals. In case you are not successful with the connection, contact a CAN MAN electrician.


Cause 1:

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

Setting of t1 and t2:

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

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


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

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


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


Cause 2:

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



Final pusher (Synchrostar II): Sensor B64.


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


Cause 3:

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



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


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


Inductive Sensor (magnetic field resistant)

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


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.

  1. Check the position of the switch!
  2. The internal battery is defect!

If you do not use the panel for a longer period (several weeks), the device should be turned off on the backside. Otherwise the internal battery will discharge and will get damaged!


The internal battery can be exchanged by opening the back cover of the unit. CM Article No. 009548


If you push the button on the right side, you are able to see the status of the integrated battery and optional available second battery.


The optional second battery is located at the back of the device.