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How to bypass / remove a generator in case of failure on the PowerCURE V2 please check link below:

CM26 bypass generator in case of failure

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.

Reason for error message:

• The Pacemaker™  capacitor bank voltage is to low.

Possible causes:

• Supply voltage mains drop down. Please check all phases even when the machine is running. Does a phase drop down?
• Check complete wiring, Are all clamps tightened?
• Check the 24Vdc supply terminals 17/18 on Pacemaker board. This 24Vdc are supplied by the welding machine and has to be always on. If the 24Vdc is missing, the precharging of capacitors works, but the main contactor will not switch on => Ubatt Error

• Check the 24Vdc output terminals 41/42. After precharging is complete, 24DC should be applied here to close the main contactor. Possibly the small print relay on the electronics board is 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.

How To:

1. Switch off cooling unit.
2. Switch off main power. Wait 10 min until the capacitors inside PM HF are discharged before removing cover.
3. Before you remove any cable, take some picture and note how they are connected.
4. Disconnect the cables and water tubes on the c-bank.
5. Disconnect the Powercable and the water tubes on PM HF unit.
6. Disconnect the signal cable (Plug Sub D 25 Pin) and the panel cable (Plug Sub D 9 Pin).
7. Disconnect the two valve cables inside PM HF.
8. Remove the PM HF and replace with new or spare unit.
9. Reconnect all cables.
10. ATTENTION: Check the coil before connecting it!
    • Coil must be dry.
    • Insulation must be in good condition!
    • All connections inside could must be fixed well.
    • See also FAQ: Sparking on the induction coil! Error: “Output overcurrent”, “CH-driver fault” or “Frequency abnormal”
11. Double check all connection before switching on the main power.
12. Compare the settings/parameter and change it if necessary. For instructions which parameters has to set and how to do please contact Can Man
13. Re-start the PowerCURE™

Reason for error message:

• The Pacemaker™ HF has detected a missing phase.

Possible causes:

• Supply voltage mains (all three phases) 400V
• Check the small fuses on the bottom of Pacemaker HF
• Check complete wiring, Are all clamps tightened?
• Measuring voltage at the input terminals on the main board (see attached picture)
• IC “OC14” or phase measurement is defective. Replace the IC, Type HCPL3700

For a Pacemaker-repair we calculate / estimate a “cycle-time” of 2 weeks, including final testing and packing. If a faster service is required, extra charges occur. In case the number of incoming repair jobs is unusual high, it might take more than 2 weeks.

Possible cause:

• Defective print.

Corrective measure:

• Replace the small print for eject station.

Possible cause:

• The power percentage is too high! If the power percentage rises up to 96%, the LED is flashing. In this case the pacemaker does not have enough spare power to regulate the current properly.

Corrective:

• To solve the problem, reduce current/frequency value or use a higher transformer step.

Cause:

Download PDF here

Problem:
The display shows the set current value, but the duty cycle is very low or 0%!

Possible cause:

• Short circuit in the welding transformer!

DO NOT ATTEMPT TO SWITCH “ON” THE CURRENT ANYMORE!
Further attempts to switch on the current, can destroy or damage the semiconductors (IGBT) in the Pacemaker!

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.

Important requirements:

1. t2 must be always higher than t1 (t2 > t1).
2. t2 and t1 must be set lower than 1 cycle time of the machine. For example, if the machine is running with 300 cans/min the cycle time is 200ms. Therefore, t2 and t1 must be set lower than 200ms.
3. To do an overlap check set  “overlap check” to “ON”. The reduced current will be set automatically to 0A. In the same window you have an additional value. If you set this for example to 10ms you have more unwelded area at the beginning and end of can.
   NOTE: If you use “overlap check” function is not necessary to switch “Ired” to “ON”.

Possible problems, if the overlap function does not work!

• If you can’t see the value t2 and t1, maybe the pacemaker is running with “Old” mode and not with “CMX” mode. Change in the setup “CT” from “Old” to “CMX”.
• No input signal on input 4 (terminal 7 and 8 on pacemaker board). If machine is running, LED behind input 4 (clamp 7 and 8) must flashing. This is the cycle signal to start the timer t2 and t1 for the overlap check.

Possible cause:

• Check your welder according checklist Conical overlap / micro leaks
• If your Pacemaker is programed to weld with sine wave (check the IBS), we can change to triangle wave form.
  • Please contact us for further instructions.

Download instruction

How to change the battery on a Pacemaker™ with integrated Qualimaker V1 electronic board:

1. Turn off the main switch of the welder.
2. Wait at least 5min to discharge the capacitors.
3. Remove all 4 nuts which are fixing the Qualimaker V1 electronic board on top of the Pacemaker™.
4. Disconnect plug 1 acc. attached picture.
5. Mark both wires 2 acc. attached picture and make a picture how they are connected.
6. Disconnect both wires 2 and insulate their ends.
7. Now the electronic board can be lifted to have access to the battery.
8. Press the emergency stop button and turn on the main switch to power the Pacemaker™: This way the settings will not be lost when changing the battery !
9. Follow the instructions for replacing the battery => Download instruction
10. After the battery has been replaced, turn off the main switch and reconnect everything.
11. Before switching on the main switch, check all connections again to make sure they are correct and tight.

Possible Cause:

Possible cause:

• Battery empty
  • order new battery together with the pliers
    CM order No. 013310 & 013311
  • How to change the battery? See FAQ How to change the RAM battery of the Pacemaker?

Using a handpanel:
When you start up your Pacemaker, the software version will be displayed during the boot process.

Alternatively the information will we displayed, when you press the key “down” several times until you get to “Info Version”: e.g. 5.27

Using a CM16 welder you will also find the info by pressing the key “down”, since the display is the same as the handpanel of a PM.

Using a X1 welder:
Tip on the *eye” icon and the Pacemaker software version is displayed on the bottom line.

Using X8 welder:

Tip on the “eye” icon and then on a second “eye” icon to get to software version info on the bottom line – check also your manual book 1 – chapter 4.6. how to find the info.

Possible cause:

• Check if the wire speed is stable and not too slow? Sometimes two cans might be welded together (no gap)!
• Check if the speed of the exit conveyor is fast enough? The gap between the cans must be minimum of 10mm.
• Clean the first light barrier and the reflector and check the adjustment!

Download PDF english

Download PDF chinese

Problem:

• % going up to 100% after some seconds of welding
• A current is dropping down after some seconds of welding
• There is a low current of only a few amp’s
• Current is dropping significantly down after some seconds of welding

Possible cause(s):

• the welding roll might be defect
  • change welding roll

• in case you use a mercury based welding roll
  • add some mercury

• the pendulum roll might be defect
  • change the pendulum roll

• in case you use a mercury based pendulum roll
  • add some mercury

• the transformer step switch might be defect
  • change transformer step switch

NOTE: The reason for the low current is due to an open circuit. The wire might be also hot in this case. If you have in general a high power percentage you might reduce the frequency.

Scroll down in the display menu until you reach the temperature display. Observe, if after crossing the switching threshold, the temperature doesn’t change, that the solenoid valve is blocked (when the 2nd thresholds are reached the message “over- or undertemperature” will be displayed).

NOTE: The error message “Ths too low (Ths = Temperature Heatsink)” might be an indication for a contaminated valve.

Possible cause:

• Welding transformer has short circuit on primary side (see How to find out that the welding transformer is damaged / broken?)
• The cable or isolation to the welding transformer is damaged
• IGBT broken
• Exchange the contacts (CM article 005640) of the main contactor, or the complete main contactor (CM article 003217).
  (NOTE: This is only applicable, if the error message shows up, when you start up the Pacemaker).
• 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.

The Pacemaker has the following options to connect the output of the weld power limiter to other systems/controls (i.e. can rejection control):

1. E-Relay
   E-Relay of Pacemaker does stop the welder if weld power limiter is active. To connect, use the clamp No. 45, 46 and 47 (potential free relay contact 47=>com, 46=>nc, 45=>no).
   To use this function, the parameter “Wld fault” in the Pacemaker settings has to be set to “E-Relay”. If weld power limiter is activated, the E-relay do switch on, welder stop and must be reset on the Pacemaker display before the welder can be restartet. Of course the operator has to check the last welded cans to make sure that no unwelded cans go to the downline.
2. +Tol output (Clamp 35/36, 35=>0V, 36=>24Vdc)
   This output is switching on if the weld power limiter is active and can be used also to activate an ejector or other function. The next can will be welded normally and +Tol output will switch off automatically. If you want to use that output, you can change the parameter “Wld fault” to “nothing”. In this case, the E-relay will not be activated and the welder can run continuously without to stop if the weld power limiter detect a can. Of course you need an additional logic for the eject timing and eject the right can.
3. +CR output (Clamp 39/40, 39=>0V, 40=>24Vdc)
   This output will be activated if the weld power limiter is active according to the parameter “WLD fault”. You can choose different settings like “CR39/40”, “CR 50ms”…
   Example: CR 50ms => Pulse of 50ms on CR output if weld power limiter detect a bad can.
4. Can Man eject unit
   With this option it is possible to eject cans and also to eject the first and last can of a series. Please contact Can Man for an offer.Attention!!! +Tol and +CR output is supplied by the internal 24Vdc of the Pacemaker electronic board. This output is not potential free!!! Use a small 24Vdc relay to connect the signal with other systems/controls.The settings of beginning and end of can (T1/T2 or IT/ET) must be set correctly, also if you don’t use the IRED function. With this timing, the weld power do switch on the current for the next can after a stop in case of contamination (overlacquering).Code to enter the system setup: down, right, left, left, up, left, right, right

• Check function of the valve
• Check water circulation to the pacemaker
• Check the water pressure

• Check function and the contamination of the ventilators.
  • If necessary clean or change them.

Check

1. Check if there is a higher trafo step
2. Lower the freqency if possible
3. Check machine insulations

If the voltage shown on the display does not correspond to the measured voltage, it can be adjusted with the potentiometer.

Possible cause, the signal “reduce current” is always active. With reduction switch on there is no measuring, that means “Ctol” and “Power Limiter”are not active.

Check the signal “reduce current”. Maybe the electronic card of the machine is defective.

• Check sensor on tool
• Check setting of t2 and t1
• Check input of reduce current signal. LED of input 4 of pacemaker board.
• Check the Max Gap setting. Factory setting 80%.
• For testing you can set Max Gap to 0% => function off. Attention! No correction of the memory if cans are removed before the ejection station.

• Check light barrier of eject station, maybe wrong adjustment or dirty.
• When the cans passing the light barrier of the eject station, the gap between the cans must be bigger than 10 mm.
• Additionally check the following possible causes here.

• Check can memory. Must be “0”, if there is no can between welding area and the reject station. For reset memory activate light barrier by hand or  use function “reset can memory”.
• Check sensor on tool or light barrier.
• Never take out can between welding area and eject station.

• Check condition and setting of the machine.
• IReg Max too low.
• Setting of the Qualimaker.

• The message “jam in welding section” means the welding sensor B6 is on for 4 seconds without switching on and off. In normal production the sensor is switching on and off for each can.
  • Check the function of the sensor!

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Possible Cause (CM16 / S, X8):