iPad does not connect to the machine. Screen remains gray and shows no values.
Possible Causes & Resolutions:
Battery of IPC is empty when:
Click here for the status LED’s of the Beckhoff PC and how to access the PC in case of a trouble shooting.
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 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!
This is the result of a wrong flexer setting!
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.
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.
NOTE: Only applicable for CMX8 with serial number until No.182 (with Linmot controller type E 1130 and E 2030)
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“.
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!
With this reading the canbody will have 1 mm overtravel.
NOTE: all timing settings are stored on the PLC and not on the memory card.
Possible cause /checklist:
Important: Switch “OFF” the sensor before you open the welding pressure!
Adjustment of the light barrier distance to eject cylinder might be wrong.
Wrong adjustment of the transport belt speed.
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
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.
Read also this checklist here.
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.
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.
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.
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.
In contrast to other machines, the roller head offset is fixed in machines of the
X- series and is therefore not adjustable.
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.
The sensors B1 and B2, which are mounted to main machine plate, need to be readjusted.
This might be possible, because the triggering is inverse (this means with a minimal distance to the sensor, it results a max. frequency.
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.
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.
The correct setting for B19 – active, should give you distance of approx. 25mm from center of the hole to the block.
A hexagonal screwhead activates the sensor B24 (center), which then opens the channel flap.
The opening time of the channel flap, can be
extended through software (see Chapter 4.5.2. in Book 1)
A hexagonal screw activates the sensor B78 (right), which provides the timing for the feeder (synchronization)!
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.
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
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.
Make sure that the “activator” screws are tightened and locked and not touching the sensors.
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.
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.
X8 with air cylinder downstacker
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.
NOTE: Only applicable for the model X8-350!
Report all steps, new or different settings, and old and new production parameters (can size, cpm, weld speed, weld current, weld frequency, current wave-form and transformer step) for an easier overview and follow-up !
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
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 seem 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 with a microscope. Store the pictures if possible!
Checklist to Avoid Flange-Cracks
Flange cracks can occur at the beginning and the end of the seam, even if all above mentioned basic parameters & settings seem to be corret.
Flange cracks can have various sources: Wrong settings on the welder, tin-plate parameters – for instant parallel rolling direction – which support such faults, worn or wrong flanger in the downline, or tin-plate parameters which do not fit to the flanger and or seamer.
For a better visual understanding put the faulty-can bodies in a water bath and inspect the leaking are with a microscope. Store the pictures if possible!
We recommend following maintenance procedures:
Safety data sheets see below:
Maintenance, cleaning and insulation check (can be used in general for any welder)
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.
− Mount the Z-bar back into the arm and measure the insulation by Ohm-meter > 10 Mega Ohm!
Check also every bearing. Attention: Most of them have ceramic balls, marked by a red point!
Make sure you are using only stainless steel screws and washers and lubricate the threads again!