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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.

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• 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!

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.

Possible cause:

• Check the air pressure on the small air regulator, the value must be around 0.5bar (pressure to engage the clutch).
  • refer also to the touch screen “Air” symbol, where you find the exact values.
• Check the air pressure on the precision air regulator, left side from synchrostar motor, to 1.6 to 2.0 bar (pressure to disengage the clutch)
  • refer again to the touch screen “Air” symbol.
• Check whether the safety clutch is engaged or not: Turn the synchrostar by hand, and see whether the motor is also turning or not. If yes, the clutch is engaged!
• If the clutch is engaged, but the error message still remains, the sensor B69 might wrong positioned:
  • Check if the LED from the sensor is OFF.
  • If the LED is still ON, turn the sensor a quarter turn counterclockwise, or until the LED is OFF. Do not turn the sensor too much counterclockwise. If the distance is too big the clutch does not stop the machine in case of a crash. To test you can adjust the precision air regulator of clutch to „0“. Now the clutch is disengaged and the sensor has to be ON.
  • Make sure that the sensor has still a clearance of about 0.5mm refer to manual Mayr EAS 450  or Mayr Clutch 0-481-325
  • Turn the synchrostar and make sure that there is no resistance coming from the sensor/clutch!

Possible causes:

• The 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.