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Circuit breaker Q5 Pacemaker trips

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.

Pacemaker: Profibus communication error

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.

Profibus problem: Speed of the drives changes during production

Problem:

Speed of the drives changes during production

Possible causes & resolutions:

Wrong position of the switch for the terminating resistor on the bus plug.
Check all switches on the complete bus system. Follow the cable thoroughly from first DP bus device (PLC) to last DP bus device. The terminating resistor switch of first and last must be set to „ON”, all other to „OFF“.
Bus connector/plug defect
Check wiring of all profibus cables, especially the connection of the cable shield inside the plug.
Problem of terminating resistor supply by last device on bus. Try to change the profibus wiring to use on another device as last client.

How to find out that the welding transformer is damaged / broken?

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

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

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Circuit breaker Q5 Pacemaker trips

Pacemaker: Profibus communication error

Profibus problem: Speed of the drives changes during production

How to find out that the welding transformer is damaged / broken?

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