Support

10 Support Entries

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:

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

IMG-20201111-WA0070.jpeg

 

Possible Causes & Resolution:

  • Turn the machine off and back on and see if the error message comes up again.
  • Check for the LED “on” at the PLC.
  • The machine isn’t showing any reaction (for example wire manual)
  • Please check the MPI-bus connection between the touch panel and the PLC.
  • Also check if all the PLC modules are properly mounted to the c-rail.
  • The machine was switched off for a longer period.
  • The PLC has an internal battery. To be sure that it can be sufficient charged, leave the machine power on for >24 hours.
  • Change the battery of the Pacemaker, see FAQ PM send error / PM receive error or welding parameter don’t match after starting the machine.

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 !

 

  1. 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 !

 

  1. 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.

 

  1. 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 !

 

  1. 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:

  1. 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.

Possible cause:

  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.

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.

NOTE:
The positions of the screws for the sensors B19, B24 and B78 have been set in the factory, and should not be adjusted. If something has changed nevertheless, you should follow the detailed description below.

 

B19

Three sensors are located on the right near the feeder drive M8.
Sensor B19 (left) controls the vacuum valve of the suction beam.

 

 

After „breaking“ the vacuum, the position of the screwhead for the sensor B19 must be active. Therefore the position should be chosen between „breaking“ the vacuum and the lowest position of the sucker unit while traveling down.

 

 

B19

The correct setting for B19 – active, should give you distance of approx. 25mm from center of the hole to the block.

 

B24

A hexagonal screwhead activates the sensor B24 (center), which then opens the channel flap.
NOTE:
The opening time of the channel flap, can be
extended through software (see Chapter 4.5.2. in Book 1)

 

 

B78

A hexagonal screw activates the sensor B78 (right), which provides the timing for the feeder (synchronization)!

NOTE:
This signal comes from the PLC in the elevating platform version, so no B78 is used in such an application.

 

 

The „active“position of the screwhead for the sensor B78, can vary depending on the rollforming speed.

 

 

B24 B78

The signal of B78, always follows the signal of B24, that means that the flap must be closed (B24), before the body pusher starts (B78). The distance, resp. the angle between the two screwheads is fix (at approx. 25 – 45°).

 

 

B19 B24 B78

The correlation of the three screwheads. View from toward the electrical cabinet. This setting is based on:
Can diameter 66 – 99mm

120 cans/min

Rollformer speed of 190m/min (49.5Hz)

 

 

With a higher rollforming speed, or if the blanc feeding is too late, or you get a damaged blank beginning, you have to move both screwheads slightly clockwise.

 

 

With a lower the speed of the rollformer and jams the blanks from the backtravelling body pusher, you have to move anticlockwise.

 

 

NOTE:
Make sure that the “activator” screws are tightened and locked and not touching the sensors.

 

NOTE:
A wrong setting of one of the sensors (B19/B24/B79) will not show a direct related error message.
An incorrect setting of B19 will cause destacking problems and the incorrect setting of B24 & B79 will cause synchronization problems.

 

The center of the calibration crown (tooling) should be
X = 2 – 3 mm
behind the center of the pendulum roller head.

 

he screw with the lock nut has a red seal and must not be changed. This is used to fix the position on the longitudinal axis of the tool carrier with regard to the welding centre.

 

NOTE:
If you have to change the setting of the calibration crown, you have to loose the lock nut and adjust with the M10 screw accordingly.

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