What causes fault code CONV-ROLLER1 (Roller Conveyor — Zone Fault / Motor Roller Fault)?

Motor roller (MDR) internal motor failed — brushless DC motor burned out. Zone controller card faulted — check LED status on zone card. Motor roller cable connector corroded or loose — 4-pin connector at roller end. Zone photo-eye blocked or failed — zone controller can't determine product presence. 24VDC power supply to zone controller insufficient — voltage sag under load

How do I fix fault code CONV-ROLLER1?

Check zone controller LED — most show GREEN for ready, RED for fault, FLASHING for specific error codes. Verify photo-eye for the zone is operational — block and unblock, watch zone controller response. Check motor roller cable connection — disconnect and reconnect the 4-pin connector at the roller. Measure 24VDC at zone controller power input — must be 24VDC +/-10% under load. Try swapping motor roller from a known-good zone — if the fault follows the roller, roller is dead. If zone card itself is faulted, try power-cycling the zone controller. Replace motor roller if confirmed dead — note roller diameter, length, and speed rating for correct replacement

Roller Conveyor — Zone Fault / Motor Roller Fault

CONV-ROLLER1

Motorized roller conveyor zone controller detected a fault in one or more zones. Motor roller not responding to run command, or zone sensor failure.

medium conveyor

conveyor roller mdr zone motor roller photo-eye

Probable Causes (ranked)

Motor roller (MDR) internal motor failed — brushless DC motor burned out
Zone controller card faulted — check LED status on zone card
Motor roller cable connector corroded or loose — 4-pin connector at roller end
Zone photo-eye blocked or failed — zone controller can't determine product presence
24VDC power supply to zone controller insufficient — voltage sag under load

Fix Steps

1 Check zone controller LED — most show GREEN for ready, RED for fault, FLASHING for specific error codes
2 Verify photo-eye for the zone is operational — block and unblock, watch zone controller response
3 Check motor roller cable connection — disconnect and reconnect the 4-pin connector at the roller
4 Measure 24VDC at zone controller power input — must be 24VDC +/-10% under load
5 Try swapping motor roller from a known-good zone — if the fault follows the roller, roller is dead
6 If zone card itself is faulted, try power-cycling the zone controller
7 Replace motor roller if confirmed dead — note roller diameter, length, and speed rating for correct replacement

Field Trick

Motor rollers (MDRs) communicate with zone controllers through their cable. If you crimp a new connector on a motor roller cable and get one wire wrong, you can burn out the zone card. Always check the cable pinout against the manufacturer diagram. Itoh Denki, Interroll, and OSRI all use different color codes.

Suggested Replacement Parts

Parts matched to fault category: Motor

Baldor/ABB 1HP TEFC Motor P/N: EM3554T 1HP, 1765RPM, 143TC frame, 230/460V, TEFC, premium efficiency

AutomationDirect $285.00 Amazon $310.00 Grainger $345.00

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

Need a deeper diagnosis with photo analysis and AI-powered troubleshooting?

Run Full Diagnosis