Support

18 Support Entries

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:

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:

Downstacker motor doesn’t move correctly to the reference position, stops or suddenly changes the direction of rotation. Display of servo controller U16 shows „IMax“ or „P03 trip“.

Possible Causes & Resolutions:

To check:

  • Mechanical condition of downstacker motor: Turn it by hand and check that everything runs smoothly.
  • Resolver mounting: Is firmly connected to the motor shaft?
  • Resolver bearings: Remove the resolver from the motor shaft and check if it is turning smoothly.
  • Resolver and motor connections: Motor and resolver are connected correctly and clamps/plugs tightened?
  • Motor windings: Disconnect the motor from the inverter and check the windings with an ohm meter (U-V,U-W,V-W). All values are equal?
  • Output servo controller: Measure the inverter output voltage when it should run (U-V,U-W,V-W). If 0V and display shows „IMax“ maybe servo controller defective.

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:

  • 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.

 

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.

 

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:

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:

  • Drives for the height change magazin and infeed system are active and stopped before reaching the position – overcurrent active.
    • Go to the mask for height change, push the reset button and the start button. The drives must reach the position without overcurrent message. If the error comes again, check the free movement of mechanical system.
  • If “SF” and “BF” on the PLC are “Red”, some drives on profibus are missing (no connection of height change position drive to profibus).
    • Check Fuse F6/F7!
    • End resistant of all profibus plugs must be “OFF”, only first and last plug “ON”.
    • Open the profibus plug on height change positioning drives, then open and close again the connectors!
    • Check the profibus cables!
    • Check the profibus module for damages or bad contacts!

Possible causes:

  • Tool plug not properly connected.
  • Plug wet or humid.
    • Blow out and dry the plug.
  • Short-circuit from the diabolo rolls or precalibration to the mounting plate. Due to the temperature sensor cables, which are guided through mounting plate, an error message could be triggered through induction.
    • Dispose the short-circuit and clean the tooling from welding spillings. Use a contact spray.

The instructions below show you how to connect the following signals: a) Line control b) Error powder unit and c) Release powder

Signal: line control

 

In order to switch off the downline due to an error, the PLC has a prepared input. To use this input, we need a potential-free signal from the downline, which is closed when the line is ready. Use the terminal E5.1 to connect the line control.

 

As soon as an error occurs, the destacking of the sheets stops and after an adjustable delay the wire-run and the remaining drives. The canbody transport continues to run slowly. This mode plus the flashing of the key „Production ON“ shows the operator the status of the line stop.

 

 

ATTENTION:
Machine begins to produce independently again, respectively after the release of the line control.

 

This input should be connected the same way as the line control. Here as well we need a potential-free relay contact of the powder unit. But this contact needs to be open, if there is any error. This signal needs to be connected to E126.7.

The production shuts off, if an error occurs. After that the operator needs to switch on the machine.

 

Signal: Release powder

 

In order to switch on the powder, we provide a change-over contact. The contact switches as soon as the production or a single can is triggered. In order to provide enough time for the initialization of the powder, the destacking is delayed by an adjustable time. Before you connect this signal, you have to remove the comb bridge (1) and the link (2), in order to make the contact potential-free.

 

Use the terminal K6.2 (A124.2).

 

NOTE:
Consult the electrical scheme of your welder to double-check the various input signals. In case you are not successful with the connection, contact a CAN MAN electrician.

 

Cause 1:

The setting of t1 and t2 is wrong. If the timing is wrong the PM cannot execute the signal, which is necessary to memorize the canbodies in the reject unit and to start the record of the graph.

Setting of t1 and t2:

t1 defines the starting point for the reduced current time window. 

t2 is the time, where the reduced current windows ends. t2–t1= thus is the timespan for the reduced current, therefore t2 > t1! 

 

NOTE:
The value of t2 and t1 needs to be smaller as the cycle of one single can.

For example:
A production of 300/min. corresponds to a cycle time of 200 ms/can. Production of 600/min. corresponds to 100ms/can.

 

NOTE:
For a more detailed explanation of timing t1 and t2, consult your manual book 2, chapter 5.6.5. “Setting of Parameter t1 & t2 for reduced Current and Overlap Check“.

 

Cause 2:

Check the inductive proximity switch B64 at the final pusher unit for function, operating distance and defect.

 

B64

Final pusher (Synchrostar II): Sensor B64.

 

Description:
Inductive proximity sensor for embeddable mounting.
Polarity: PNP
Output: NO. or NC.
Operating distance: 2mm

 

Cause 3:

Check the tool switch B6 in the calibration tool for function, operating distance and defect.

 

B6

The position of the welding sensor B6, can be almost flush. Just make sure that you do not get scratches on the canbodies.

 

The height of the sensor can be adjusted here (see arrow).

 

Inductive Sensor (magnetic field resistant)

Mounting mode: flush
Function principle: inductive/normally open Rated operating distance: 3 mm

 

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

Download PDF here

Possible causes:

  • No supply of a slave on the bus system.
    • Check supply of all slaves.
      Emergency stop must be released.
  • Address of slave on Profibus is wrongly adjusted.
    • Check setting of all DIP switches on the Lenze bus module and on the Linmot controller.
      You can find the correct setting on the wiring diagram.
  • Wrong position of the switch for end resistant on the bus plug.
    • Check all switches on the complete bus system. Seriously follow the cable from PLC to the last slave. First plug and plug of last slave must be set to ON, all other plugs to OFF.

  1. Check the position of the switch!
  2. The internal battery is defect!

NOTE:
If you do not use the panel for a longer period (several weeks), the device should be turned off on the backside. Otherwise the internal battery will discharge and will get damaged!

 

NOTE:
The internal battery can be exchanged by opening the back cover of the unit. CM Article No. 009548

 

If you push the button on the right side, you are able to see the status of the integrated battery and optional available second battery.

 

The optional second battery is located at the back of the device.

 

All Can Man content is now also available on the Soudronic Group website.
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All Can Man content is now also available on the Soudronic Group website.
Where do you want to continue your journey?