What causes fault code CONV-015 (Conveyor Indexing Position Error)?

Index encoder missed pulses or lost reference. Clutch/brake unit slipping — not stopping precisely. Index photoeye dirty or misaligned — not confirming position. PLC index counter error — missed or double-counted products. Motor drive deceleration profile not tuned for indexing accuracy

How do I fix fault code CONV-015?

Verify index sensor — clean and align position detection photoeye. Check encoder — verify pulse count matches physical positions. If clutch/brake, check air pressure and disc wear. Review PLC index counter logic — verify timing with product flow. Tune servo or VFD deceleration for crisp stop at index position. Check mechanical alignment of index pins or tooling

Conveyor Indexing Position Error

CONV-015

Indexing conveyor stopped at wrong position. Product not aligned with station for filling, labeling, or other operations.

medium conveyor packaging

conveyor indexing position encoder clutch

Probable Causes (ranked)

Index encoder missed pulses or lost reference
Clutch/brake unit slipping — not stopping precisely
Index photoeye dirty or misaligned — not confirming position
PLC index counter error — missed or double-counted products
Motor drive deceleration profile not tuned for indexing accuracy

Fix Steps

1 Verify index sensor — clean and align position detection photoeye
2 Check encoder — verify pulse count matches physical positions
3 If clutch/brake, check air pressure and disc wear
4 Review PLC index counter logic — verify timing with product flow
5 Tune servo or VFD deceleration for crisp stop at index position
6 Check mechanical alignment of index pins or tooling

Field Trick

Put a mark on the belt at the exact station position. Run 10 index cycles and see how far the mark drifts. More than 1/4 inch? Tune the decel or check the clutch.

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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