What causes fault code PAL-DISCHARGE1 (Palletizer Discharge Conveyor — Full Pallet Not Clearing)?

Discharge conveyor VFD or motor faulted — check VFD display. Discharge area full — previous pallet not picked up by forklift. Pallet jammed on discharge conveyor — broken pallet board caught on conveyor frame. Discharge pallet present photo-eye blocked — detecting pallet that's not there (false full). Transfer mechanism between palletizer and discharge conveyor failed — roller or chain drive issue

How do I fix fault code PAL-DISCHARGE1?

Check if a pallet is physically blocking the discharge — have forklift remove it. Check discharge conveyor motor/VFD — clear any faults and restart. Inspect the discharge conveyor path for pallet debris or obstructions. Verify discharge photo-eyes — clean and confirm correct operation. Check transfer mechanism — chains, rollers, or pop-up transfers that move the pallet from palletizer to discharge. If automated pallet wrapper is inline, check wrapper status — a faulted wrapper stops pallet flow

Palletizer Discharge Conveyor — Full Pallet Not Clearing

PAL-DISCHARGE1

Completed pallet on the palletizer discharge conveyor is not advancing to the pickup area. Palletizer cannot start next pallet because discharge area is not clear.

medium palletizer conveyor

palletizer discharge conveyor full pallet forklift pickup

Probable Causes (ranked)

Discharge conveyor VFD or motor faulted — check VFD display
Discharge area full — previous pallet not picked up by forklift
Pallet jammed on discharge conveyor — broken pallet board caught on conveyor frame
Discharge pallet present photo-eye blocked — detecting pallet that's not there (false full)
Transfer mechanism between palletizer and discharge conveyor failed — roller or chain drive issue

Fix Steps

1 Check if a pallet is physically blocking the discharge — have forklift remove it
2 Check discharge conveyor motor/VFD — clear any faults and restart
3 Inspect the discharge conveyor path for pallet debris or obstructions
4 Verify discharge photo-eyes — clean and confirm correct operation
5 Check transfer mechanism — chains, rollers, or pop-up transfers that move the pallet from palletizer to discharge
6 If automated pallet wrapper is inline, check wrapper status — a faulted wrapper stops pallet flow

Field Trick

The most common cause of discharge conveyor blockage is forklift operators falling behind on pallet pickup. Before troubleshooting the conveyor, radio the forklift driver. If the pickup area has 4 pallets stacked up, the problem isn't the conveyor — it's a resourcing issue. The machines don't have the problem, the process does.

Suggested Replacement Parts

Parts matched to fault category: Photoelectric Sensor

Banner QS18VP6D Photoelectric Sensor P/N: QS18VP6D Diffuse mode, 18mm barrel, 100mm range, PNP

AutomationDirect $65.00 Amazon $72.00 Grainger $85.00

IFM Efector O5D100 Photoelectric Sensor P/N: O5D100 Diffuse reflection, M18, 50-1000mm range, IO-Link

AutomationDirect $85.00 Amazon $95.00 Digikey $90.00

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

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