Question/Problem

Troubleshooting faults related to shaft mounted encoders: motion faults, tracking, mis-diverts

Environment

-Shaft mounted encoder

-Boss, ICW, PLC, or MC4

Answer/Solution

• Verify encoder dip switch settings (with the exception of Hoehner encoders because they don't come with dipswitches). Our electrical layouts show what the encoder settings should be set at. If these settings are set wrong, this will constitute to motion faults
• Verify the phoenix connector, mounting of the encoder on the shaft and the belden cable
• Verify the belt tensioning and tracking on the conveyors.
• Verify the encoder ticks in ICW
  a. Make sure we are seeing cycle counts on the encoder during the conveyor in run state. This can be done by manually forcing the drive in local mode. An example is shown below: Encoders are part of Digital inputs under Support center in ICW
  b. If there is another section that uses an encoder with the same PPR settings,reset the encoder counts for both and run both sections manually at the same speed and see if the encoder being troubleshot gets the same number of cycles.
  c. If we don’t see any cycle counts, or if the cycles do not match another encoder with the same settings at the same speed, we will need to replace the encoder. Verify the correct part number and dip switch settings when replacing an encoder. Dip switch settings can be verified with electrical drawings.
  
  
   
• Look at the events/alarms screen for related events on the conveyor section. For example, if it is section 32001, look for drive faults events for DR32001. A lot of times a drive not in ready state/faulted or if the drive start is disabled this will trigger encoder faults.
  
  

  

  

  
  
  
  Drive fault DR31005 event as seen below in blue but the alarm in red stated END31005 faulted
  
  
• It is also important to check the status on the VFD for the associated conveyor section and encoder. Verify the drive is not forced on, not in local mode or not in profibus mode.
  

Related items

Tech sheet: https://www.ttco.com/media/pdf/HS20-P64AJ.PDF

Internal Notes

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Reason for confidentiality

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Template updated 2022-09-20 kwk Pending approval