Support

36 Support Entries

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!

 

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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.

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.

Download PDF here

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.

NOTE:
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.

NOTE:
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
B30

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.

NOTE:
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.

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

Possible cause:

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

Possible Cause:
The position of the infeed arm might have shifted, due to a crash or loose screws!

double check the correct position.

 

Therefore insert „0“ to the can height setting and press „GO“.

NOTE:
If you ever changed the overtravel setting in the tuning level, set this value to „1“.

 

Now measure the distance from the infeed arm to center of the welding roll.

 

The correct reading should be: 216 mm!

NOTE:
With this reading the canbody will have 1 mm overtravel.

 

Find the correct position by undoing the four fixing screws of the infeed arm!

 

NOTE:
This adjustment described above, is only applicable for the old type of CMX8, since the new version has a slot to prevent this issue.

Possible cause:

  • No supply of a slave on the bus system.
    • Check supply of all slaves.
  • Address of slave on Profibus is wrongly adjusted.
    • Check the linmot controller. The correct setting you can find on the wiring diagram.
  • Wrong position of the switch for end resistant on the bus plug.
    • Check all switches on the complete bus system. Follow the cable seriously from PLC to last slave. First plug and plug of last slave must be set to ON, all other plugs to OFF.

Checklist:

  • Set the roll clearance to 30-50% of the sheet thickness.
    • refer to the manual.
  • Do you have red springs in use for the upper front roll?
    • reduce the spring tension and check the spring color.
  • Spring pressure too low:
    • Tension the red/black springs with 3 – 3.5 revolutions.
    • Check the roll clearance with a dial indicator.
  • Rollformer motor too weak?
    • Provide us with the nameplate and a photo of the motor.
  • Change the frequency inverter of the rollformer motor to 87Hz technique.
    • This is the new standard of the CM X8.
  • Do you have a two-piece catching plate around the lower welding arm (Rollformer 420/540)?
    • This helps to guide overrounded canbodies back into the Z-rail.
  • Have you mounted a inner mandrel in the canal (Rollformer 420/540)
    • This also helps to guide overrounded canbodies back into the Z-rail.
  • Catching canal: Is the interior measurement of the two shells corresponding to each other?
    • If the interior diameter is too big, too open-rounded canbodies might not be correctly conducted into the canal.
  • Catching canal:
    Does the canal flap works properly?

    • The flap might even touch the canbody, which is being welded. Only the a perfect adjusted flap fulfills their purpose.
  • Check the upper rollformer plate: Use a dial indicator to see, if there are back and forth or up and down movements.

Possible cause:

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


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

Possible cause /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: Display > 30.0 daN!
  • If the welding pressure is secured, you can bypass the signal with a trial jumper, see diagram page PM:
    • 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!

Possible Cause:

  1. Check air supply for the cylinder.
  2. Eject cylinder must push the canbodies inthe center, the can must move verticallyaway from eject cylinder.
  3. Second light barrier is always ON.Sensor dirty or bad adjustment.
    LED on light barrier must be ON without can, OFF if a can is detected.
  4. Control wiring of first and second light barrier according electrical diagram.
  5. Make sure the faulty can is really ejected, means does not touch the edge of the bin and jumps back.
    => Use a fixed channel underneath the eject station, instead of a mobile bin!

Adjustment of the light barrier distance to eject cylinder might be wrong.

Wrong adjustment of the transport belt speed.

NOTE:
The ejected can should whether touch the can before nor the following.

Eject pulse cylinder has to fit to production speed:

Recommendation: 150-200msfor<100cpm 100-150msfor100-200cpm

80-100msfor200-400cpm

Place a canbody between the second light barrier and check the LED „LD3“ on the eject print (inside the Pacemaker).
Must be „ON“.

The autoreset needs to be “OFF”. Therefore the can memory will not be reset automatically.

Check, if your hardware parameters are set correctly, according to one of the three layouts.
=> See layouts below!


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

Read also this checklist here.

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

 

he screw with the lock nut has a red seal and must not be changed. This is used to fix the position on the longitudinal axis of the tool carrier with regard to the welding centre.

 

NOTE:
If you have to change the setting of the calibration crown, you have to loose the lock nut and adjust with the M10 screw accordingly.

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

In it’s uppermost position, the sucker should lie slightly above the sheet inlet, between the first pair of rollers.

 

If the setting has to be changed, the screw on the setting ring will have to be loosened.

 

NOTE:
Further information regarding the exchange of sucker unit of the feeder can be found in Chapter 6. Changeover.

 

To perform a good timing, the best way is to disconnect the air hose of the cylinder and block it. In that way you can manually lift the sucker unit and find the correct timing.

 

If you move down the sucker unit to the blank, the vacuum will be activated. Then move up the unit together with the blank until the vacuum breaks.

 

The correct timing of “breaking” the vacuum is, when the blank just arrives between the roller pair.

In contrast to other machines, the roller head offset is fixed in machines of the
X- series and is therefore not adjustable.

 

If you have, due to whatever reason to adjust this setting, first make sure what the result of the offset is.

 

To adjust this offset, you have to loose the two M8 screws of the holder from the welding pressure cylinder.

 

Additionally you have to loose four M6 screws (1- two are shown), which are fixing the plate (2). Now you can shift the position of pendulum roller slightly in the various hole play.

 

NOTE:
Do not make any adjustments on this shaft!

 

Double-check the offset value again and tighten all screws securely.

 

The sensors B1 and B2, which are mounted to main machine plate, need to be readjusted.

 

Here you have another viewpoint of the two sensors.

 

The reason, why the wire is still running is, that a distance “x” in the picture is too big. Therefore reduce the clearance for both sensors B1 and B2 too a minimum of 0.1mm.

Download PDF here

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

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

NOTE:
The positions of the screws for the sensors B19, B24 and B78 have been set in the factory, and should not be adjusted. If something has changed nevertheless, you should follow the detailed description below.

 

B19

Three sensors are located on the right near the feeder drive M8.
Sensor B19 (left) controls the vacuum valve of the suction beam.

 

 

After „breaking“ the vacuum, the position of the screwhead for the sensor B19 must be active. Therefore the position should be chosen between „breaking“ the vacuum and the lowest position of the sucker unit while traveling down.

 

 

B19

The correct setting for B19 – active, should give you distance of approx. 25mm from center of the hole to the block.

 

B24

A hexagonal screwhead activates the sensor B24 (center), which then opens the channel flap.
NOTE:
The opening time of the channel flap, can be
extended through software (see Chapter 4.5.2. in Book 1)

 

 

B78

A hexagonal screw activates the sensor B78 (right), which provides the timing for the feeder (synchronization)!

NOTE:
This signal comes from the PLC in the elevating platform version, so no B78 is used in such an application.

 

 

The „active“position of the screwhead for the sensor B78, can vary depending on the rollforming speed.

 

 

B24 B78

The signal of B78, always follows the signal of B24, that means that the flap must be closed (B24), before the body pusher starts (B78). The distance, resp. the angle between the two screwheads is fix (at approx. 25 – 45°).

 

 

B19 B24 B78

The correlation of the three screwheads. View from toward the electrical cabinet. This setting is based on:
Can diameter 66 – 99mm

120 cans/min

Rollformer speed of 190m/min (49.5Hz)

 

 

With a higher rollforming speed, or if the blanc feeding is too late, or you get a damaged blank beginning, you have to move both screwheads slightly clockwise.

 

 

With a lower the speed of the rollformer and jams the blanks from the backtravelling body pusher, you have to move anticlockwise.

 

 

NOTE:
Make sure that the “activator” screws are tightened and locked and not touching the sensors.

 

NOTE:
A wrong setting of one of the sensors (B19/B24/B79) will not show a direct related error message.
An incorrect setting of B19 will cause destacking problems and the incorrect setting of B24 & B79 will cause synchronization problems.

 

Possible cause:

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

Possible cause:

This can only happen on higher can heights. The canbody to be welded, is extending with its back into the rollforming area, while the next tin plate is coming out of rollformer and touches the backside of the tin plate. The sharp edge of the rollforming plate scratches paint away. This paint is being welded thereafter in the seam.

 Correction:

  1. Reduce the Linmot cycle time, but not less than 500 ms (access with password customer 1). The can is now pushed faster into the welding area. This might already solve the problem.
  2. Adjust the timing of the feeder delay and compare to Linmot pusher (see manual book 1, chapter 4.5.3.)
  3. Increase rollformer speed if necessary, to reduce the rollforming process, because of delayed feeder.
  4. Try step 2 and 3 til ok.

Corretive:

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

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

Corretive:

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

Possible cause:

  1. The calibration crown is adjusted too close (too much overlap).
    This can cause a high resistance.
  2. Switch of machine and move the slider by hand. It must move smoothly.
  3. Slider dirty – since the slider of the linear motor contains strong magnets, remove dust or small metallic particles from the slider (see picture beside).
    To do this, remove the front cover.
  4. Wrong adjustment of curve time. Curve time means the duration for one complete move of linear motor. It must be shorter then one machine cycle!Example: Production speed => 120cpm => Machine cycle 500ms => curve time must be lower then 500ms

     

X8 with air cylinder downstacker

  1. Check the function of the valve Y1 for downstacker; Watch the LED on the valve for consitent timing / on – off switching and, if inconsitent, please check output on PLC (Vipa output A4.6, Beckhoff output BA117 1/9), wiring and plug to valve or replace solenoid or entire valve)
  2. Check if the cylinder is worn, therefore check for are air leaks in both positions and to much backlash between piston rod and cylinder body.
  3. Check cylinder / piston movement by removing air hoses (or air pressure) and move the piston in and out (up and down) manually


NOTE:
 If you did remove the bracing, reassemble correctly. Check the insulation and tighten the self-locking nut only slightly, that the connection can adjust itself.

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!

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“!(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 correct 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!

 

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  • 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:

  • 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!

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

Procedure:

  •   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!

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

Download PDF here