Alarm List for Can Filler DVD 50

Component Colored dot Meaning

Machine paneling Blue Door open
Yellow Area selected
Can stopper Blue Can stopper closed due to machine fault
Yellow Can stopper closed automatically
Infeed conveyor Blue The infeed conveyor is stationary
Yellow Can shortage
Flashing yellow Half capacity
Outfeed conveyor Blue Conveyor running
Yellow Can backup
Flashing yellow Half capacity
Emergency stop Yellow with red flashing dot Emergency stop actuated
Filler computer Blue Synchronous fault
Yellow Filling fault

No. Fault description Solution

F00148 Blue: Synchronous fault The machine has not yet reached the Let Filler operate for 2 or 3 rotations
machine zero point

The switching flag for detection of the Reset the position of Zero Position
synchronous clock is in the wrong position. Sensor

The proximity switch for detection of the Test functionality of the proximity
Synchronous clock is faulty. sensor and replace if necessary

The proximity switch for detection of the Test functionality of the proximity
Machine timing is faulty. sensor and replace if necessary
F0105 to F0108 Blue: Paneling A paneling door is open Ensure all machine doors are closed
The door contact switch is not available or is Test functionality of the proximity
faulty. sensor and replace if necessary
F0152 Blue: Fault Infeed conveyor not running
Yellow: Can shortage The infeed sensor (proximity switch) on the Test functionality of the proximity
infeed conveyor is faulty. sensor and replace if necessary
The drive of the infeed conveyor is blocked or Test motor power and protector
defective.
F0015 Blue: Fault Outfeed conveyor not running.
Defective backup switch on the outfeed Test functionality of the proximity
conveyor. sensor and replace if necessary
The drive of the outfeed conveyor is blocked Test motor power and protector
or defective.
 2) Fault
3) address of the disrupted Profibus
subscriber 4)the
address of the disrupted Profibus system

F0141 Fault DP Mastersystem/Profibus

Eliminate the reason of overload and
replace the circuit breaker if necessary
then operate it again if there is no
another problem

F0002 to F0004 Circuit breaker in.. specify machine area"

The protective motor switch in switch cabinet Test functionality of the motor & the
F0005 S1 has triggered cable & the circuit breaker & the drive

The frequency converter is not The frequency converter signals a fault.

F0017 ready Test functionality of the drive

The thermistor motor switch in switch Test functionality of the motor & the
F0019 Thermistor protection cutout cabinet S1 has triggered cable & the circuit breaker & the drive

Ensure that all the bus is

The bus connection through which the connected and that F0141 of the
individual electronic components Profibus has no alarm
communicate (data and signal exchange) is
interrupted.
One of the external electronic components
connected to the bus connection, or its
F0041 Bus connection batch fault transfer passage, is interrupted.
Ensure that the cable & its insulation
are in a good condition. Also the filler
computer is operating well
The signal line between the programmable
Data transfer fault PLC - Filler controller (PLC) and the filler computer is
F0150 computer interrupted or disrupted
Safety: Test of paneling area +P... The regular inspection of the safety devices Open the door & close it again in the
Was not performed (machine paneling including wiring) was not specified area then reset the filler.
F0097 to F0100 carried out.
Safety: Test of emergency stop The regular inspection of the emergency stop Press the emergency stop
button then release it again.
was not performed devices was not carried out. Press the glowing
F0101
“Acknowledgment Fault”
button on the filler screen then
reset control voltage
An attempt was made to open a locked door. You must release the magnetic lock
Safety: Manipulation of paneling before opening the door
F0112 detected, blocking time active
Safety: Maintenance/service safety One of the service doors on the machine is All service doors must be closed and
then reset control voltage and ladder
area not closed open
The KHS ladder for reaching the filler turret is Is in place and replace broken sensors
F0124 not in the ladder mount on the outside of the
machine paneling.
 Safety: Timeout connection No communication between the safety Ensure that every bus is connected
PNOZmulti <-> PLC control system and the machine control between Pilz & PLC.
F0096 system (PLC)

Safety: PLC safety fault (Fault, O There is a fault in Pliz multi Read the fault on Pilz and then reset
F0102 fault, I Fault or Diag)
Safety: Internal EMERGENCY STOP An EMERGENCY STOP has been triggered, Ensure the connection then release
F0109 message e.g. at the can sealer the emergency button
Safety: External EMERGENCY STOP Ensure the connection then release
F0110 message the emergency button
Safety: Timeout connection One or more safety control systems are not in Make acknowledge by
PNOZmulti <-> PNOZmulti RUN mode. cutting 24V for short time
F0111 (see wiring diagram)
Ensure the connection and replace
components as required
Safety: Fault with return circuit Actuation of the output contactor and the
F0113 to F0116 and F0119 and F0120 contactor: Paneling area +P.... response are not correct (both "1" or "0").
Safety: Fault with return circuit Ensure the connection and replace
components as required
contactor: Paneling area +P.... Actuation of the output contactor and the
F0125 to F0128 Secondary response are not correct (both "1" or "0").
Safety: Fault with speed monitor The speed transducer on a driving motor is replace components as required
(nActual not equal to nTarget): defective.
F0121 Diagnosis Data transmission is interrupted.
Safety: Fault with The type-dependent permissible Ensure setting required speed and
make acknowledge
speed monitor (nActual speed/output is exceeded.
not equal to A star was moved by hand.
F0122 nTarget): safe speed
Safety: Fault with speed monitor A driving unit is turning even though it should Check Motor & CPU then make
acknowledge
(nActual not equal to nTarget): be stopped
F0123 safe stop A star was moved by hand.
One or more lubricant distributors Test Grease path
or lubrication points are blocked. Test valve functionality and replace
A magnetic valve in the supply of a main If required
Greasing fault
distributor is faulty.
A magnetic valve in the supply of a main
F0009 distributor is faulty.
A can has fallen over in the area of the infeed Inspect empty cans infeed
screw. This has pushed the infeed screw Test infeed sensor functionality
Infeed screw fault
outwards
F0023 The infeed screw sensor is defective.
Replace can stopper The "Replace can stopper star" function Close changing stopper program
F0013 star" function enable enable is still activated or was activated (see
activated. chapter "Operator guidance").
Bell actuator malfunction Insufficient water supply to the filler. Inspect water quantity to the filler
(insufficient The water filter is clogged. Clean water filter
water throughput for The magnetic valve is faulty. Replace water infeed valve
F283 the roller lubrication There is no control air at the control valve. Ensure there is pressurized air for
of the bell actuator) The flow monitor is faulty. valve operation
The water nozzles are clogged. Replace flow monitor
Clean water nozzles
 Filler height adjuster
invalid positive difference;
F039;F040 Filler height
adjuster invalid negative
difference
Height adjustment
limit switch activated
at bottom; Height
adjustment limit
F049; switch activated at
F050 top
The protective motor
switch in switch cabinet
F005 S1 has triggered
Height adjustment
F064 process not completed
The height adjuster
moves incorrectly at
the inner ring (filler
F341 carousel)
The height adjuster
moves incorrectly at
the outer ring (control
F342 cam)
F343; Prohibited height
F344 adjustment standstill
Roller guide fault
F0011
Tulip supply pressure, up/down R1 Insufficient air supply to the filler turret.
not
OK; Supply pressure
air R1 not OK (the
pressure of the air
supply to the pneumatic
control box on
F353; the filler turret has
F359 fallen below 3.0 bar)
Working pressure air
R1 not OK (filling
valves) (the pressure
in the pneumatic
control box on the
filler turret has fallen
F360 below 5.5 bar)
The difference between the Recalibrate Bowl level sensor
outer and inner ring has
exceeded the limit value of 1.6
mm.
Height adjuster is at its lower Rotate bowl to correct position
or upper limit.
The motor protection for the Check motor, its cable, its circuit
breaker, PLC signal and then reset
operation key ON
height adjustment motor of the
outer or inner ring was actuated.
The actual value has not Continue on Bowl Level Setting
reached the setpoint value. Program till reach setpoint
The height adjuster moves Ensure the direction and change if
opposite to the specified
direction. required
Ensure the direction and change if
The height adjuster moves
opposite to the specified required
direction.
The height adjuster motor is Replace the motor or cable feeding
faulty or there is a break in the the motor
cable.
The bell rod of a filling valve is not in the Ensure column movement and
bottom position. replace if it’s bent and clean it as
The sensor (proximity switch) after the roller well
guide for checking the position of Change senor with another new one
the bell rods is defective
Ensure air quantity and pressure
Air pressure too low. Fix any leakage
Leak in air supply. Change pressure sensor with
The pressure monitor for the filling valve another new one
control system is faulty.
The pressure controller for the filling valve
control system is faulty.
Insufficient air supply to the filler turret. Air Ensure air quantity and pressure to
pressure too low be 6 bar
Leak in air supply. Fix any leakage
 Tulip pressure not OK (the tulip Insufficient air supply to the filler turret. Air Ensure air quantity and pressure to
pressure pressure too low be 6 bar
has fallen below the setpoint. Leak in air supply Fix any leakage
There The pressure monitor for the filling valve Change pressure sensor with
are no cans in the filler) control system is faulty another new one
The pressure controller for the filling valve Change pillows.
control system is faulty
The bellow in the bell actuator are faulty.
F354
It was ascertained that several
F0142 Several underfilled cans consecutive cans were underfilled
Defective electronic filler computer An output module for the filling valves in the A KHS Technician must inspect and
F0144 module filler computer is defective change this module
The probe card specified in the fault text is A KHS Technician must inspect and
F0170 to F0175 Failure of probe card faulty. change this module
No pressure build up in the ring The "Pre-pressurize" operating mode is not Select this option
bowl selected. Reset Pressurization time and
The pressurization time and/or counter counter
Change sensor with another one
pressure is incorrect. Ensure Pressure sensor reading
The proximity switch for can detection is and replace if required
faulty. Make Zero position for the filler
The centering bells are not pressed in
adequately.
The filler is still not synchronous.
No cans are filled The cans are not pressurized Ensure there is no fault (cans are
The "Fill" operating mode is not selected not pressurized)
The cans are not pressed in. Select filling program from screen
The centering bells are not pressed in Ensure bowl height program
Ensure pressure monitor reading for
adequately. centering bells
The counter pressure and/or pressurization Ensure timing of pressure
time is incorrect. equilibrium for this type then set
The bellow in the bell actuator are faulty. counter pressure higher than
The filling valve control has no control air saturation pressure by 1bar
pressure. Check pillows
Check infeed air pressure
The flow meters are not working.
Check flowmeter operation
The proximity switch for the can sensor is Check infeed sensor operation
faulty or set incorrectly. Set the filler
The filler is still not synchronous . Check air pressure feeding valves is
The product control valve does not work. from 5 to 6 bars
The level probes in the ring bowl are not Check (I/P) operation
working. Check Probe Signal
 Ring bowl filling level in
impermissible range. (The ring
bowl filling level is below the
setpoint level set at the operator
terminal.) Impermissible value:
ring bowl filling level. (The ring
bowl filling level exceeds the
setpoint level set at the operator
terminal.)
F0449
Pressurization and ring bowl
pressure too low. (The
pressurization and ring
bowl pressure is below the
setpoint level set at the operator
F0450 terminal.)
Return gas pressure too low. (The
return gas pressure is below the
setpoint set at the operator
F0451 terminal.)
Steam temperature
F0840 too low
F0842, F0843 Detergent temperature too low
F0844 Infeed cleaning pressure too low
Insufficient product supply to the filler Check product supply
Product pressure at the filler infeed too low is enough
Defective product control valve Check product
Defective position controller pressure is higher
No control air at the product control valve than filler pressure by
Defective pressure sensor 1 bar
Check infeed valve is
working and no
leakage
Check control valve
is working well
Check there is
pressurized air
Check pressure
sensor functionality
Insufficient pressurization gas Check there is
supply to the filler pressurized air
Defective pressurization pressure Check pressure
controller sensor functionality
Defective pressure sensor
Defective return gas control Check pressure sensor functionality
Defective pressure sensor & replace if necessary
Defective temperature sensor Check steam and temperature
Defective steam generation heater sensor
Defective temperature sensor Check (CIP) and temperature
Defective CIP system heater sensor
Insufficient detergent supply to the filler Check detergent supply quantity to
the filler
 Prepared By Reviewed By Approved By

Name Abanoub Ehab Samer Medhat Paula Magdy Guirgis Basta Sameh Nady

Title Packaging Maintenance Safety Manager Maintenance Packaging Manager

Engineer Engineer Manager

Contact Person Abanoub Ehab Samer Medhat

E-mail abanoub.ehab@heineken.com samer.medhat@heineken.com