Support

Problem:

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

Possible Causes or Resolutions:

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

Problem:

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

Possible Causes & Resolutions:

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

Problem:

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

Possible Causes & Resolutions:

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

Problem:

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

Possible Causes & Resolutions:

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

Problem:

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

Possible Causes & Resolutions:

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

Problem:

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

Possible Causes & Resolutions:

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

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

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

Problem:

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

Possible Causes & Resolution:

Excel Spreadsheet – CM Electrical Components List

Problem:
Display shows „Could not activate iPad“

Possible causes & resolutions:

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

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

Please follow the below instructions carefully:

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

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

2. Cooling water / emulsion distribution station on X7:

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

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

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

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

Please check them if needed !

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

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

4. Copper wire / copper wire profiling unit:

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

5. Welding parameters:

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

6. Other possible errors:

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

Problem:

iPad does not connect to the machine. Screen remains gray and shows no values.

Possible Causes & Resolutions:

• Connection via Wi-Fi
  • In the settings, check whether the iPad has connected to the correct Can Man Wi-Fi
  • If no Can Man Wi-Fi is visible, check router/wireless access point.
    ➔ Restart router/wireless access point. If still no Can Man Wi-Fi is visible, the router/wireless access point has lost the settings or is broken. Contact Can Man via by opening a new ticket.
• Connection via Cable
  • Check all plug connections of the network cable between IPC and iPad
  • Check iPad adapter power supply. The adapter must always be powered, otherwise the connection will not work.

Battery of IPC is empty when:

• System Date and Time (Error Log) not correctly displayed and getting lost when powering off the IPC.

To Do:

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

Download regrooving datasheet

Download PDF here

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

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

Possible causes:

1. The serial reduce (Powerfoil) is active
2. Timing from the welding pressure to vacuum “ON” is too short
3. Wrong setting of t1 & t2
4. Mechanical setting might need to be adjusted
   (only for unwelded sections at the beginning)

Possible causes:

• Check the blank cutting tolerances and blank squareness.
• Adjust the rollformer (roller shaft clearance and spring pressure) according to the manual.
• Control if there is a high difference in the tin plate hardness, by rollforming 10 bodies without welding. Put them on the floor in line and compare the difference in the rollforming overlap.
• Check if the destacking process is going well. Make sure the tin plate is guided tight, and the separating air is positioned well.
• Control the timing of the tin plate transport in between two transport fingers.
• Make sure that the guidance channel is properly adjusted. The intersection to the precalibration of the calibration crown is most important.
• Check the position of each (inside and outside!) transport finger compared to rollformed canbody.
• Check the offset of each finger pair itself. Move the canbody slowly forward (X1 and X6 by slow mode function) and observe eventual shaking of the canbody until the welding point.
• If a third finger exists: The third finger must be 0.5 mm behind the upper main pusher fingers!
• Reset the calibration crown completely. Make sure that each precalibration roller is turning easily! If needed lubricate their shafts slightly and clean the roller afterwards. Make sure that these rollers are as close as possible to each other!
• Measure the speed of the flat belt in the calibration crown:
  The speed must be absolutely identical with the copper wire speed!
• Measure the overtravel: Short can heights shall have 1 mm overtravel.
• The center of the diabolo roller (equal to the center of calibration crown) shall be 1–2 mm before the welding center.

• The fan unit can be removed. Check whether the fan is correctly mounted (screwed).
• The fans can also be removed and cleaned if dirty.
• Replace the defective fan unit!

Download PDF

An overvoltage suppressor (or surge suppressor) is an appliance designed to protect electrical devices from voltage spikes. A surge suppressor attempts to regulate the voltage supplied to an electric device by either blocking or by shorting to ground voltages above a safe threshold.

These surge suppressors are built in to the latest Pacemaker models and machine controls (from 2009).

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

Attention!!!

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

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.

Possible cause:

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

Download PDF here

Possible cause /checklist:

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

This is the result of a wrong flexer setting!

Possible cause:

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

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

Possible cause:

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

Possible Causes & Resolutions:

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

Checklist:

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

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

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

Possible cause:

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

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

Possible Cause (CM16 / S, X8):

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

Read also this checklist here.

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

Download PDF here

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

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

Possible cause:

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

Possible cause:

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

 Correction:

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

Corretive:

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

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

Corretive:

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

Problem:

Error message: “Jam canbody transport”

Possible Causes & Resolutions:

• Calibration crown: Possibly is adjusted too close (too much overlap). This can cause a high resistance. Readjust according manual.
• Slider condition: Switch of machine and move the slider by hand. It must move smoothly. Since the slider of the linear motor contains strong magnets, remove dust or small metallic particles from the slider (see picture beside). To do this, remove the front cover.
• Wrong adjustment of curve time: Curve time means the duration for one complete move of linear motor. It must be shorter then one machine cycle! Example: Production speed => 120cpm => Machine cycle 500ms => curve time must be lower then 500ms.
• Enable signal of plc lost (Error message Linmot controller “User Err:Motion Cmd in Wrong St.“): Check wiring between PLC module and Linmot controller. Check PLC module. Clean the contact surfaces between the PLC modules with contact spray.

Additionally checkpoints for X8 with air cylinder downstacker

• Function of the valve Y1 for downstacker: Watch the LED on the valve for consitent timing / on – off switching. If inconsitent, please check output on PLC (Vipa output A4.6, Beckhoff output BA117 1/9), wiring and plug to valve or replace solenoid or entire valve.
• Cylinder condition: Possibly is worn, therefore check for are air leaks in both positions and to much backlash between piston rod and cylinder body. Removing air hoses (or air pressure) and move the piston in and out (up and down) manually.

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

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

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

Basic parameters & settings to be checked first

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

Checklist to Avoid Micro Leaks

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

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

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

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

Checklist to Avoid Flange-Cracks

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

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

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

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

• 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!

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

Download PDF here