--- title: "Appendix 1: Alarms" description: "## 1. E-Stop Active **CONDITION** The emergency stop input is active. **POSSIBLE CAUSE(S)** - E-Stop push button is pressed. **TROUBLESHOOTING** **1** **Release the emergency stop button** **2** **Push RESET push button to clear.** **3** **If the alarm will not clear**…" url: "https://www.cv-tek.com/docs/mark-iii-plus/appendix-1-alarms/" updated: "2026-10-05" category: Mark III Plus+ --- # Appendix 1: Alarms ## 1. E-Stop Active **CONDITION** The emergency stop input is active. **POSSIBLE CAUSE(S)** - E-Stop push button is pressed. **TROUBLESHOOTING** **1** **Release the emergency stop button** **2** **Push RESET push button to clear.** **3** **If the alarm will not clear** Replace the contacts of the emergency stop button and verify the wiring. ## 2. Low Gas Pressure **CONDITION** The low gas pressure switch input is active. **POSSIBLE CAUSE(S)** - This alarm will not activate if the active recipe has a 0 in all of the gas timers. **TROUBLESHOOTING** **1** **If the alarm will not clear** Verify that gas is hooked up to the machine **2** **If gas is hooked up to the machine** Change the gas pressure sensor and verify the wiring. ## 3. PLC Module 0 Faulted **CONDITION** The PLC has faulted **TROUBLESHOOTING** **1** **Set the switch on the PLC to stop and then run twice** **2** **If the RUN LED does not stay green after resetting twice** The PLC will need to be replaced. ## 4. PLC Module 1 Faulted **CONDITION** The digital input card (Slot 1 on the IO rack) has faulted. **POSSIBLE CAUSE(S)** - Failed digital output card - Shorted or failed field device - Wiring fault on one of the outputs **TROUBLESHOOTING** **1** **Remove the terminal strip on the front of the card** And cycle power to the machine to see if the fault clears. **2** **If the fault does not clear** Remove the terminal strip from the front of the output card. **3** **If the fault does clear** Check the wiring for each of the inputs. Note that a quick way to see which input is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which input is causing the fault. ## 5. PLC Module 2 Faulted **CONDITION** The safety input card (Slot 2 on the IO Rack) has faulted. **POSSIBLE CAUSE(S)** - Failed digital output card - Shorted or failed field device - Wiring fault on one of the outputs **TROUBLESHOOTING** **1** **Remove the terminal strip on the front of the card** And cycle power to the machine to see if the fault clears. **2** **If the fault does not clear** Replace the input card. **3** **If the fault does clear** Check the wiring for each of the inputs. Note that a quick way to see which input is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which input is causing the fault. ## 6. PLC Module 3 Faulted **CONDITION** The analog input card (Slot 3 on the IO Rack) has faulted. **TROUBLESHOOTING** **1** **Remove the terminal strip on the front of the card** And cycle power to the machine to see if the fault clears. **2** **If the fault does not clear** Replace the input card. **3** **If the fault does clear** Check the wiring for the RTD and the vacuum pressure sensor. ## 7. PLC Module 4 Faulted **CONDITION** The digital output card (Slot 4 on the IO rack) has faulted **TROUBLESHOOTING** **1** **Remove the terminal strip on the front of the card** And cycle power to the machine to see if the fault clears. **2** **If the fault does not clear** Replace the output card. **3** **If the fault does clear** Check the wiring for each of the outputs. Note that a quick way to see which output is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which output is causing the fault. ## 8. PLC Module 5 Faulted **CONDITION** The safety output card (Slot 5 on the IO rack) has faulted. **TROUBLESHOOTING** **1** **Remove the terminal strip on the front of the card** And cycle power to the machine to see if the fault clears. **2** **If the fault does not clear** Replace the output card. **3** **If the fault does clear** Check the wiring for each of the outputs. Note that a quick way to see which output is causing the issue is to remove them all and put them back one-by-one until the fault reappears to determine which output is causing the fault. ## 9. Below Temperature Range **CONDITION** The temperature is too far below the setpoint value to allow the machine to run **POSSIBLE CAUSE(S)** - The machine takes time to heat up at the beginning (often upwards of 10 minutes), and this alarm will be present until the machine is in range of the temperature setpoint. **TROUBLESHOOTING** **1** **If the temperature value does not reach the setpoint after a sufficient amount of time** Determine if the bar is physically getting hot (you should be able to determine this by placing hands a few inches away from the outside of the bar, the air should be hot). **2** **If the bar is not getting hot** Verify the wiring and function of the heater SSR and heater and replace if necessary **3** **If the bar is getting hot and the temperature on the screen is not increasing** check the RTD wiring and replace the RTD if necessary. ## 10. Above Temperature Range **CONDITION** The temperature is too far above the setpoint value to allow the machine to run. **POSSIBLE CAUSE(S)** - This alarm is commonly caused by reducing the temperature setting significantly lower than the current temperature value. **TROUBLESHOOTING** **1** **If the temperature is still increasing after getting this fault** Verify if the LED is on for the heater SSR.. **2** **If the LED is off and the bar is still hot** Verify the wiring and function of the heater SSR and heater and replace as necessary. ## 11. RTD Open Wire **CONDITION** The analog input card is not reading a value from the RTD. **TROUBLESHOOTING** **1** **Verify the wiring and replace the RTD if the wiring is correct.** **2** **If the issue still persists** Replace the analog input card. ## 12. Vacuum Pump Proof Fault **CONDITION** The input for the feedback from the vacuum pump contactor is not active. **TROUBLESHOOTING** **1** **Check the wiring of the vacuum pump contactor.** **2** **If the wiring is correct and the issue persists** Replace the contactor. ## 13. Vacuum Sensor Open Wire **CONDITION** The analog input card is not reading a value from the vacuum pressure sensor. **TROUBLESHOOTING** **1** **Check the wiring of the vacuum sensor.** **2** **If the wiring is correct and the issue persists** replace the sensor. **3** **If the issue still persists** Replace the analog input card. ## 14. Probe 1 Up Timeout **CONDITION** The input for the probe 1 up reed switch is not active after a set time while the output to lower the probes is not active. **TROUBLESHOOTING** **1** **Verify that the probe is up and that the green LED on the reed switch is active**. **2** **If the probe is up** Ensure that the reed switch is adjusted properly to illuminate the LED when the probe is up. **3** **If the LED is on and the probe is up** Check the reed switch wiring and replace if necessary. **4** **If the probe is not up** Verify there are no obstructions preventing the probe from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the probes, and check that the air lines are connected properly to the manifold and air cylinder. ## 15. Probe 1 Down Timeout **CONDITION** The input for the probe 1 up reed switch is active after a set time while the output to lower the probes is active. **TROUBLESHOOTING** **1** **Verify that the probe is down and that the green LED on the reed switch is not on.** **2** **If the probe is down and the green LED is off** Check the wiring of the reed switch and replace if necessary. **3** **If the probe is up** Verify there are no obstructions preventing the probe from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the probes, and check that the air lines are connected properly to the manifold and air cylinder. ## 16. Probe 2 Up Timeout **CONDITION** The input for the probe 2 up reed switch is not active after a set time while the output to lower the probes is not active. **TROUBLESHOOTING** **1** **Verify that the probe is up and that the green LED on the reed switch is active.** **2** **If the probe is up** Ensure that the reed switch is adjusted properly to illuminate the LED when the probe is up. **3** **If the LED is on and the probe is up** Check the reed switch wiring and replace if necessary. **4** **If the probe is not up** Verify there are no obstructions preventing the probe from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the probes, and check that the air lines are connected properly to the manifold and air cylinder. ## 17. Probe 2 Down Timeout **CONDITION** The input for the probe 2 up reed switch is active after a set time while the output to lower the probes is active. **TROUBLESHOOTING** **1** **Verify that the probe is down and that the green LED on the reed switch is not on.** **2** **If the probe is down and the green LED is off** Check the wiring of the reed switch and replace if necessary. **3** **If the probe is up** Verify there are no obstructions preventing the probe from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the probes, and check that the air lines are connected properly to the manifold and air cylinder. ## 18. Two Hand Start Buttons Released **CONDITION** The dome buttons for the two hand start were released before the cycle was completed. **TROUBLESHOOTING** **1** **Verify that the buttons are clean and dry as the buttons are capacitive and moisture and grease on the surface can interfere with performance.** **2** **Check button wiring and ensure the cable connection is tight.** ## 19. Internal Use Only N/A ## 20. Left Bag Stretcher Up Timeout **CONDITION** The input for the probe 2 up reed switch is active after a set time while the output to lower the probes is active. **TROUBLESHOOTING** **1** **Verify that the left bag stretcher is up and that the green LED on the reed switch is active.** **2** **If the bag stretcher is up** Ensure that the reed switch is adjusted properly to illuminate the LED when the bag stretcher is up. **3** **If the LED is on and the bag stretcher is up** Check the reed switch wiring and replace if necessary. **4** **If the bag stretcher is not up** Verify there are no obstructions preventing the bag stretcher from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder. ## 21. Right Bag Stretcher Up Timeout **CONDITION** The input for the right bag stretcher up reed switch is not active after a set time while the output to lower the probes is not active. **TROUBLESHOOTING** **1** **Verify that the right bag stretcher is up and that the green LED on the reed switch is active.** **2** **If the bag stretcher is up** Ensure that the reed switch is adjusted properly to illuminate the LED when the bag stretcher is up. **3** **If the LED is on and the bag stretcher is up** Check the reed switch wiring and replace if necessary. **4** **If the bag stretcher is not up** Verify there are no obstructions preventing the bag stretcher from rising. Also, check the manifold regulator to verify that there is proper air pressure to lift the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder. ## 22. Left Bag Stretcher Down Timeout **CONDITION** The input for the left bag stretcher up reed switch is active after a set time while the output to lower the bag stretchers is active. **TROUBLESHOOTING** **1** **Verify that the bag stretcher is down and that the green LED on the reed switch is not on.** **2** **If the bag stretcher is down and the green LED is off** Check the wiring of the reed switch and replace if necessary. **3** **If the bag stretcher is up** Verify there are no obstructions preventing the bag stretcher from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder. ## 23. Right Bag Stretcher Down Timeout **CONDITION** The input for the right bag stretcher up reed switch is active after a set time while the output to lower the bag stretchers is active. **TROUBLESHOOTING** **1** **Verify that the bag stretcher is down and that the green LED on the reed switch is not on.** **2** **If the bag stretcher is down and the green LED is off** Check the wiring of the reed switch and replace if necessary. **3** **If the bag stretcher is up** Verify there are no obstructions preventing the bag stretcher from lowering. Also, check the manifold regulator to verify that there is proper air pressure to drop the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder. ## 24. E-Stop Safety IO Fault **CONDITION** There is a safety IO fault with the E-Stop circuit. **POSSIBLE CAUSE(S)** - This happens when the contacts are in an inconsistent state (meaning one open and the other closed) for too long of a time period. **TROUBLESHOOTING** **1** **Check the wiring of the E-Stop contact blocks** And replace them if there are no wiring issues. ## 25. Cycle Start 1 Safety IO Fault **CONDITION** There is a safety IO fault with the Cycle Start 1 PB circuit. **POSSIBLE CAUSE(S)** - This happens when the contacts are in an inconsistent state (meaning both contacts open or closed) for too long of a time period. **TROUBLESHOOTING** **1** **Check the wiring of the button** And replace it if there are no wiring issues. ## 26. Cycle Start 2 Safety IO Fault **CONDITION** There is a safety IO fault with the Cycle Start 2 PB circuit. **POSSIBLE CAUSE(S)** - This happens when the contacts are in an inconsistent state (meaning both contacts open or closed) for too long of a time period. **TROUBLESHOOTING** **1** **Check the wiring of the button** And replace it if there are no wiring issues. ## 27. Jaw Closed Prox Safety IO Fault **CONDITION** There is a safety IO fault with the Jaw Closed Prox circuit. **POSSIBLE CAUSE(S)** - This happens when the contacts are in an inconsistent state (meaning one open and the other closed) for too long of a time period. **TROUBLESHOOTING** **1** **Check the wiring of the prox switch** And replace it if there are no wiring issues. ## 28. MCR Proof Fault **CONDITION** The input for the feedback on the MCR safety relay is active when the output for the relay coil is energized. **TROUBLESHOOTING** **1** **Check the wiring of the safety relay.** If the wiring is correct, replace the relay. ## 29. Jaw Close CR Proof Fault **CONDITION** The input for the feedback on the jaw close safety relay is active when the output for the relay coil is energized. **TROUBLESHOOTING** **1** **Check the wiring of the safety relay.** If the wiring is correct, replace the relay. ## 30. Jaw Close Stage 1 Timeout **CONDITION** The input for the jaw close stage 1 reed switch is not active when the output for the jaw close stage 1 is energized. **POSSIBLE CAUSE(S)** - The most common reason is that the reed switch is not adjusted properly. **TROUBLESHOOTING** **1** **Verify that when the jaw is closed in the stage 1 position that the green LED is illuminated on the reed switch.** Adjust the reed switch if necessary. **2** **If the green LED is illuminated and the alarm persists** Check the wiring of the reed switch **3** **If the jaw is not closing** Verify that there are no obstructions to the jaw. Also verify that the electronic pressure regulator is wired and functioning correctly. **4** **Once these are verified, if the issue persists** Verify the air lines are connected properly to the manifold and air cylinder. ## 31. Jaw Full Close Timeout **CONDITION** The input for the jaw close stage 2 proximity switch is not active when the output for the jaw close stage 2 is energized. **TROUBLESHOOTING** **1** **Verify that when the jaw is closed in the stage 2 position that the jaw closed proximity switch is being made.** Adjust the proximity switch if necessary. **2** **If the proximity switch is being met and the alarm persists** Check the wiring of the proximity switch. **3** **If the jaw is not closing** Verify that there are no obstructions to the jaw. Also verify that the electronic pressure regulator is wired and functioning correctly. **4** **Once these are verified, if the issue persists** Verify the air lines are connected properly to the manifold and air cylinder. ## 32. Jaw Open Timeout **CONDITION** Either the input for the jaw close stage 1 reed switch or the jaw close stage 2 proximity switch is active while the output to close the jaw is not energized. **TROUBLESHOOTING** **1** **If the jaw is physically open** Check which input is active. **2** **When you find which input is energized** Check the wiring and replace the switch as needed. **3** **If the jaw is not opening** Verify that there are not obstructions. **4** **Check the functionality and wiring of the electronic pressure regulator** Verify that the air lines are connected properly between the air cylinder and the manifold. ## 33. Vacuum Pressure Timeout **CONDITION** The vacuum pressure could not hit the setpoint value for an extended time during the cycle. **TROUBLESHOOTING** **1** **Check for leaks or clogs in the vacuum lines**. **2** **Verify the wiring of the vacuum pressure sensor.** ## 34. Third Bag Stretcher Up Timeout **CONDITION** The input for the third bag stretcher up reed switch is not active after a set time while the output to lower the probes is not active. **TROUBLESHOOTING** **1** **Verify that the third bag stretcher is up and that the green LED on the reed switch is active** **2** **If the bag stretcher is up** Ensure that the reed switch is adjusted properly to illuminate the LED when the bag stretcher is up **3** **If the LED is on and the bag stretcher is up** Check the reed switch wiring and replace if necessary. **4** **If the bag stretcher is not up** Verify there are no obstructions preventing the bag stretcher from rising **5** **Check the manifold regulator** Verify that there is proper air pressure to lift the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder. ## 35. Third Bag Stretcher Down Timeout **CONDITION** The input for the third bag stretcher up reed switch is active after a set time while the output to lower the bag stretchers is active. **TROUBLESHOOTING** **1** **Verify that the third bag stretcher is down and that the green LED on the reed switch is not on.** **2** **If the bag stretcher is down and the green LED is off** Check the wiring of the reed switch and replace if necessary. **3** **If the bag stretcher is up** Verify there are no obstructions preventing the bag stretcher from lowering **4** **Check the manifold regulator** Verify that there is proper air pressure to drop the bag stretchers, and check that the air lines are connected properly to the manifold and air cylinder.