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.

Excel Spreadsheet – CM Electrical Components List

• 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!

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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:

• 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 Causes & Resolutions:

• No supply of a Profibus participant (slave) on the bus system.
  • Check 24Vdc supply of Linmot controller. Is supplied by 24Vdc terminal X10. For more details check wiring diagram.
  • Check 400Vac supply of Pacemaker. The circuit breaker Q5 may have tripped. For more details check wiring diagram.
• Address of Profibus on Linmot controller is set wrong.
  • Check the two rotary switch S1 and S2 on front side of Linmot controller. Both should be set according wiring diagram.

• Dip switch for interface on Linmot controller is set wrong.
  • Check the Dip switch S3 on bottom side of Linmot controller. Dip switch 4 must be set to ON to activate the Profibus interface, all other must be set to OFF.

• 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 first to last Profibus participant . Plug of first Profibus participant and plug of last Profibus participant must be set to ON, all other 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

• PLC program has been lost due to empty ram battery and missing program on the memory card. Red LED IF is on.
  • Program has to be loaded again by DP/MPI adaptor and laptop with installed Siemens Step7 software or from memory card (MMC) with program file. => Contact Canman.
  • Possibly PLC or memory card are defective and has to be replaced.
  • Important: The ram battery in the PLC cannot be replaced! This is charged when the machine is switched on and guarantees that the program is retained for a maximum of 30 days. If the PLC loses the program due to an empty ram battery, it automatically loads it from the memory card (MMC) when the machine is started. Of course only if a memory card is inserted and there is a valid file on it.

Vipa 214 Manual