What causes fault code ASRS-001 (AS/RS Crane Position Error)?

Position encoder fault — missed pulses or lost reference. Crane hit obstruction during travel — products overhanging from rack. Homing sequence interrupted by fault or E-stop. Motor drive fault caused uncontrolled stop. Position calibration data corrupted in PLC

How do I fix fault code ASRS-001?

Re-home the crane from the designated home position. Inspect rack face for protruding products or damaged uprights. Check travel encoders — verify pulse count on manual jog. Verify home position sensors are clean and functional. Review position calibration table in PLC/WMS — compare to physical measurements. If encoder replaced, recalibrate all bay positions

AS/RS Crane Position Error

ASRS-001

Automated storage/retrieval crane reports position mismatch. Actual position does not match commanded location within tolerance.

high asrs

asrs crane position encoder calibration

Probable Causes (ranked)

Position encoder fault — missed pulses or lost reference
Crane hit obstruction during travel — products overhanging from rack
Homing sequence interrupted by fault or E-stop
Motor drive fault caused uncontrolled stop
Position calibration data corrupted in PLC

Fix Steps

1 Re-home the crane from the designated home position
2 Inspect rack face for protruding products or damaged uprights
3 Check travel encoders — verify pulse count on manual jog
4 Verify home position sensors are clean and functional
5 Review position calibration table in PLC/WMS — compare to physical measurements
6 If encoder replaced, recalibrate all bay positions

Field Trick

Jog the crane to a known physical reference point (like bay 1, level 1) and compare the encoder reading to what the PLC expects. The difference tells you how far off calibration is.

Suggested Replacement Parts

Parts matched to fault category: Encoder

Omron E6B2-CWZ6C Rotary Encoder P/N: E6B2-CWZ6C-1024P/R Incremental, 1024 PPR, 5-24VDC, NPN open collector

AutomationDirect $85.00 Amazon $75.00 Digikey $95.00

Autonics E40S8-1024-3-T-24 Encoder P/N: E40S8-1024-3-T-24 40mm body, 1024 PPR, totem pole output, 8mm shaft

AutomationDirect $65.00 Amazon $58.00

Prices are estimates. Verify part numbers match your equipment before ordering.

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