What causes fault code PAL-ELEV1 (Palletizer Elevator / Lift Table — Position Fault)?

Elevator drive chain stretched — position doesn't match encoder reading. Elevator VFD faulted — overcurrent from overloaded pallet or mechanical binding. Position encoder on elevator lost signal — cable or encoder failure. Elevator guide rails binding — misalignment or lack of lubrication. Load on pallet exceeded elevator weight capacity — motor can't lift

How do I fix fault code PAL-ELEV1?

Check elevator VFD for fault codes — clear and investigate root cause. Verify elevator moves freely without load — jog up and down in manual mode. Check elevator drive chain tension — adjust or replace if excessively stretched. Inspect elevator guide rails — clean and lubricate, check for binding or wear marks. Verify encoder feedback — watch position count on PLC display while jogging elevator. Check pallet weight — verify total pallet load doesn't exceed elevator rating

Palletizer Elevator / Lift Table — Position Fault

PAL-ELEV1

Pallet elevator or lift table did not reach the commanded position. Failed to index down for the next layer or failed to position at the correct height for discharge.

high palletizer

palletizer elevator lift table position chain encoder

Probable Causes (ranked)

Elevator drive chain stretched — position doesn't match encoder reading
Elevator VFD faulted — overcurrent from overloaded pallet or mechanical binding
Position encoder on elevator lost signal — cable or encoder failure
Elevator guide rails binding — misalignment or lack of lubrication
Load on pallet exceeded elevator weight capacity — motor can't lift

Fix Steps

1 Check elevator VFD for fault codes — clear and investigate root cause
2 Verify elevator moves freely without load — jog up and down in manual mode
3 Check elevator drive chain tension — adjust or replace if excessively stretched
4 Inspect elevator guide rails — clean and lubricate, check for binding or wear marks
5 Verify encoder feedback — watch position count on PLC display while jogging elevator
6 Check pallet weight — verify total pallet load doesn't exceed elevator rating

Field Trick

When an elevator indexes down for each layer, it must drop exactly one product height. If the drop distance is off by 1/4 inch per layer and there are 8 layers, the last layer is 2 inches off. This causes the top layer to slam down (too much drop) or not clear the squaring plates (too little drop). Calibrate the layer height precisely.

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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