What causes fault code PAL-LAYER1 (Palletizer Layer Forming — Row Push Fault)?

Product jammed in the layer forming table — misaligned or fallen product blocking the row. Row pusher cylinder not extending fully — air pressure low or cylinder seal leaking. Row counter photo-eye missed a product — incorrect row count caused premature push. Product orientation wrong — turned product doesn't fit in the row pattern. Row guide rails too tight or too loose for product size — products jamming or falling out of alignment

How do I fix fault code PAL-LAYER1?

Clear the jammed products from the layer forming table. Check row pusher cylinder — manually fire it from the PLC or valve override to verify full stroke. Verify air pressure at the cylinder regulator — typically 60-80 PSI. Check row counter photo-eye — clean lens and verify alignment with product detection zone. Adjust layer forming table guide rails to match product dimensions — snug with 1/4 inch clearance. If product orientation is inconsistent, check upstream turner/orienter mechanism

Palletizer Layer Forming — Row Push Fault

PAL-LAYER1

Palletizer layer forming area failed to push a complete row of products. Row pusher did not complete its stroke, or products were not properly positioned before the push.

medium palletizer

palletizer layer row pusher forming pattern

Probable Causes (ranked)

Product jammed in the layer forming table — misaligned or fallen product blocking the row
Row pusher cylinder not extending fully — air pressure low or cylinder seal leaking
Row counter photo-eye missed a product — incorrect row count caused premature push
Product orientation wrong — turned product doesn't fit in the row pattern
Row guide rails too tight or too loose for product size — products jamming or falling out of alignment

Fix Steps

1 Clear the jammed products from the layer forming table
2 Check row pusher cylinder — manually fire it from the PLC or valve override to verify full stroke
3 Verify air pressure at the cylinder regulator — typically 60-80 PSI
4 Check row counter photo-eye — clean lens and verify alignment with product detection zone
5 Adjust layer forming table guide rails to match product dimensions — snug with 1/4 inch clearance
6 If product orientation is inconsistent, check upstream turner/orienter mechanism

Field Trick

When a palletizer has intermittent row push problems, watch the product flow onto the layer forming table. If products arrive with inconsistent gaps, the row fills unevenly and the push misaligns items. Fix the product spacing at the infeed conveyor, not at the palletizer. The palletizer can only work with what you give it.

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