What causes fault code PAL-LAYER2 (Palletizer Layer Forming — Pattern Error)?

Wrong recipe selected on HMI — pattern doesn't match the current product. Product size changed — new product is different dimensions than programmed pattern. Layer forming photo-eye miscounting — missed product or double-counted. Row turning mechanism not rotating products to correct orientation for alternating layers. Product damaged or deformed — doesn't hold shape in the pattern

How do I fix fault code PAL-LAYER2?

Verify the correct recipe/pattern is selected on the HMI for the current product. Check product dimensions against the programmed pattern — width, length, and height must match. Inspect layer forming photo-eyes — clean and verify accurate product counting. Check product turner/rotator — verify it rotates products correctly for alternating layers. If product dimensions changed, update the palletizer recipe with new product measurements. Run a test layer in slow mode — watch each product position to identify where the pattern breaks down

Palletizer Layer Forming — Pattern Error

PAL-LAYER2

Palletizer detected that the formed layer does not match the programmed pattern. Product count, orientation, or spacing is incorrect for the current recipe.

medium palletizer

palletizer pattern layer recipe product size orientation

Probable Causes (ranked)

Wrong recipe selected on HMI — pattern doesn't match the current product
Product size changed — new product is different dimensions than programmed pattern
Layer forming photo-eye miscounting — missed product or double-counted
Row turning mechanism not rotating products to correct orientation for alternating layers
Product damaged or deformed — doesn't hold shape in the pattern

Fix Steps

1 Verify the correct recipe/pattern is selected on the HMI for the current product
2 Check product dimensions against the programmed pattern — width, length, and height must match
3 Inspect layer forming photo-eyes — clean and verify accurate product counting
4 Check product turner/rotator — verify it rotates products correctly for alternating layers
5 If product dimensions changed, update the palletizer recipe with new product measurements
6 Run a test layer in slow mode — watch each product position to identify where the pattern breaks down

Field Trick

When switching products on a palletizer, ALWAYS run the first 3 layers in slow mode and watch. Programmers often set up patterns in the office and don't account for real-world product variation. A case that's 1/4 inch wider than the drawing can cause every layer to be off by an inch at the far edge.

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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