What causes fault code CONV-SORT1 (Sortation System — Diverter Fault)?

Pneumatic cylinder on diverter not firing — solenoid valve stuck or air supply low. Diverter confirm sensor not seeing the diverter in position — sensor misaligned or failed. Air pressure too low for diverter speed — regulator set too low or compressor can't keep up. Diverter mechanical pivot jammed — product debris or bearing seized. PLC output to solenoid valve not firing — check output module LED

How do I fix fault code CONV-SORT1?

Check air pressure at the diverter — gauge should read 60-80 PSI minimum. Manually actuate the solenoid valve using the manual override (small button or pin on the valve body). If cylinder moves with manual override, problem is electrical — check PLC output and solenoid valve coil. If cylinder doesn't move with manual override, problem is pneumatic — check air supply, cylinder seals, tubing. Inspect diverter confirm sensors — block/unblock and verify PLC sees the input change. Check for product debris in the diverter pivot area — clean and lubricate. Verify PLC logic is commanding the diverter at the right time based on barcode scan or tracking data

Sortation System — Diverter Fault

CONV-SORT1

Sortation conveyor diverter mechanism failed to actuate or did not confirm position. Product may have been sent to the wrong destination or continued on the main line.

high conveyor

conveyor sortation diverter pneumatic solenoid cylinder

Probable Causes (ranked)

Pneumatic cylinder on diverter not firing — solenoid valve stuck or air supply low
Diverter confirm sensor not seeing the diverter in position — sensor misaligned or failed
Air pressure too low for diverter speed — regulator set too low or compressor can't keep up
Diverter mechanical pivot jammed — product debris or bearing seized
PLC output to solenoid valve not firing — check output module LED

Fix Steps

1 Check air pressure at the diverter — gauge should read 60-80 PSI minimum
2 Manually actuate the solenoid valve using the manual override (small button or pin on the valve body)
3 If cylinder moves with manual override, problem is electrical — check PLC output and solenoid valve coil
4 If cylinder doesn't move with manual override, problem is pneumatic — check air supply, cylinder seals, tubing
5 Inspect diverter confirm sensors — block/unblock and verify PLC sees the input change
6 Check for product debris in the diverter pivot area — clean and lubricate
7 Verify PLC logic is commanding the diverter at the right time based on barcode scan or tracking data

Field Trick

Diverter solenoid valves on high-speed sortation systems cycle millions of times a year. Replace the solenoid valve coils proactively every 18 months — they cost $15 each. A failed coil during peak shipping season means missed sorts and angry customers.

Suggested Replacement Parts

Parts matched to fault category: Solenoid Valve

SMC SY3120 Solenoid Valve P/N: SY3120-5LZD-M5 5/2 way, 24VDC, M5 ports, direct piping, 0.15-0.7 MPa

AutomationDirect $32.00 Amazon $28.00 McMaster-Carr $45.00 Grainger $42.00

Festo VUVG Solenoid Valve P/N: VUVG-LK14-M52-AT-G18-1R8L 5/2 way, 24VDC, G1/8 ports, spring return

AutomationDirect $55.00 Amazon $62.00 Grainger $70.00

Air Pressure Regulator + Filter Combo P/N: AW30-03BG SMC AW series, 3/8 NPT, 5-125 PSI, with gauge and bowl guard

AutomationDirect $38.00 Amazon $32.00 McMaster-Carr $48.00

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

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