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



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




-Shaft mounted encoder

-Boss, ICW, PLC, or MC4




  • 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:


Internal Notes




Reason for confidentiality





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.


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Template updated 2022-09-20 kwk Pending approval

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Published on 8/8/2019.
Last Modified on 11/27/2022.
Last Modified by Joe Lowry.
Article has been viewed 5511 times.
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