Article: KB-11202
How to:
Conveyor stopped, Motor is not running, overload alarm.
Skill required to complete this article: Controls and level is No Skill Level Association.

Conveyor is not working automatically. Motor runs when forcing output, but no Motor running input received.
Overload Alarm



Opto 22 I/O System

Motor runs when output forced ON



Overload alarm means the corresponding input does not come on when the output is energized for a motor. When the output is forced on, the contactor engages and the motor turns on. A continuing overload alarm condition indicates a problem with the input circuit. There are 4 main possibilities for this: failed fuse on the input board, failed input module, failed contact or wiring failure.

Use the troubleshooting chart below to resolve:




With output forced, voltage present at motor contactor AUX, voltage present at input terminal, module indicator OFF. Adjacent input also not responding to input voltage

Failed pico fuse

Replace pico fuse

With output forced, voltage present at motor contactor AUX, voltage present at input terminal, module indicator OFF. Adjacent input responds to input voltage

Failed input point

Replace Opto quad pack

With output forced, voltage present at motor contactor AUX, voltage not present at input terminal.

Wiring error

Re-terminate signal wire

With output forced, voltage not present at motor contactor AUX,

Aux contact failure

Replace contactor or Aux contact




Related items

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Internal Notes

 We  should check the electric connections and wiring first . It should be tighten and fixed .

check if there is no overload alarm.

Reason for confidentiality

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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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Published on 5/13/2022.
Last Modified on 9/1/2023.
Last Modified by Kurt Kimnach.
Article has been viewed 331 times.
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