What causes fault code CONV-012 (Conveyor Merge Collision Detected)?

Merge timing incorrect — both lines releasing simultaneously. Gap between products too small — not enough space for merge. Photoeye at merge point dirty or misaligned. PLC merge logic error — priority not being enforced. Speed differential too large between merging conveyors

How do I fix fault code CONV-012?

Clear jammed products from merge point. Verify merge photoeye — clean lens, check alignment. Review merge timing in PLC — adjust gap timer to prevent simultaneous release. Match conveyor speeds at merge — both should be same speed or receiving slightly faster. Check merge priority logic — one line must yield to other. Run at reduced speed to observe merge behavior

Conveyor Merge Collision Detected

CONV-012

Products collided at a conveyor merge point. Photoeye detected overlapping or jammed products at merge zone.

medium conveyor packaging

conveyor merge collision timing gap

Probable Causes (ranked)

Merge timing incorrect — both lines releasing simultaneously
Gap between products too small — not enough space for merge
Photoeye at merge point dirty or misaligned
PLC merge logic error — priority not being enforced
Speed differential too large between merging conveyors

Fix Steps

1 Clear jammed products from merge point
2 Verify merge photoeye — clean lens, check alignment
3 Review merge timing in PLC — adjust gap timer to prevent simultaneous release
4 Match conveyor speeds at merge — both should be same speed or receiving slightly faster
5 Check merge priority logic — one line must yield to other
6 Run at reduced speed to observe merge behavior

Field Trick

The receiving conveyor after the merge should run 10-15% faster than the feeding conveyors. This creates a natural gap and prevents pile-ups.

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