Article: KB-10899
How to:
How to Troubleshoot Shaft mounted encoder
Skill required to complete this article: Controls and level is Beginner.

1.            Summary / Overview / Purpose

Author: Omer Mohammed (MO)

**Audience: Open to tech support and customer


                        “How to” troubleshoot Encoders

2.            Requirements


3.            Procedure / Body

Problem addressed:

                        Troubleshooting encoders issues on sorter related to:

  1. Motion faults
  2. Mis-tracking
  3. Miss diverting
  4. Belt tensioning/Mechanical problems


                        This article will cover the necessary steps for troubleshooting encoders on the shoe sorter and InControlWare® environment.

2.            Requirements

  1. InControlWare(ICW)
  2. Shaft encoders on IntelliSort Shoe Sorter

3.            Procedure / Body

  1. Introduction to Encoders

    The hollow shaft encoder fits onto an existing shaft and converts shaft rotation into square wave output pulses to provide an accurate and reliable means of digitizing position, rate, or length of travel. The number of pulses per each revolution of the shaft is determined by setting configuration switches. Flexible mounting brackets are available to secure the encoder without rigidly mounting it to the machine frame. The purpose of the encoder is to track the speed of the conveyor and return it back to the system.

    It consists of three parts: Disc encoder, Pheonix connector and cable.


    1. Device manufacturer: Photocraft
    2. Type: Shaft mount Encoder
    3. P/N: 23009400
    4. Layout:

    1. Dip switch settings:






  2. Troubleshooting

Motion faults

An example of an alarm in ICW:

The motion faults are triggered when ICW detects the conveyor running overspeed/under speed to what the system is requesting it to run. There is an offset of +/- 10(standard) to the requested speed. If the actual conveyor speed goes beyond or below this speed the motions faults are thrown. To address this issue please follow the steps below as a part of troubleshooting:

  1. Verify encoder dip switch settings. Our electrical layouts show what the encoder settings should be set at. If these settings are set wrong, this will constitute to motion faults
  2. Verify the phoenix connector, mounting of the encoder on the shaft and the belden cable
  3. Verify the belt tensioning and tracking on the conveyors.
  4. Verify the encoder ticks in ICW
    1. 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




    1. If we don’t see any cycle counts, 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.




  5. 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



  6. 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.


4.         Supporting External Documentation


Tech sheet:

Some of our intelligrated tickets related to encoders: TS-00322849 and TS-00323255






4.            Recovery or Back out procedure


5.            Supporting external documentation

  See front page

6.            Additional publication information




Information in this document is subject to change without notice and does not represent a commitment on the part of Intelligrated. This information is typical of the questions and general advice given; however, your particular case and circumstances may produce different results or require different recommendations. Therefore, use of this information is not a suitable replacement for contacting Intelligrated Technical Service engineering for specific recommendations and solutions to your application.


No part of this article may be reproduced or transmitted in any form or by any means including recording, or information storage and retrieval systems, for any purpose without the express written permission of Intelligrated. All information contained within the article is private and confidential and the sole property of Intelligrated.


In no event, shall Intelligrated be liable for any damages whatsoever including, without limitation, damages for loss of business profits, business interruption, loss of business information, or other pecuniary loss, even if Intelligrated has been advised of the possibility of such damages. Because some states do not allow the exclusion or limitation of liability for consequential or incidental damages, the above limitation may not apply to you.



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Published on 8/8/2019.
Last Modified on 8/8/2019.
Last Modified by Mark Thompson.
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