Pallet Wrapper fault
Pallet Wrapper Stops Mid-Cycle
A pallet wrapper that stops partway through a wrap cycle is usually a sensor, interlock, drive or position fault — the machine has detected an out-of-range condition and stopped rather than completing the cycle.
Does this match your fault?
Common symptoms
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Machine stops at the same point in the cycle every time
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Stops at random points — no obvious pattern
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Fault code shows on display when it stops
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Machine stops then restarts on its own
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Turntable stops but carriage keeps moving
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Completes some wraps but not others
What causes this
Typical causes
Position sensor fault
The machine uses position sensors to know where the carriage and turntable are in the cycle. A dirty, misaligned or failed sensor causes a stop when position cannot be confirmed.
Safety interlock triggered
A guard, door or safety mat has been triggered mid-cycle. Can be caused by a faulty switch reading intermittently rather than an actual safety event.
Drive overload or thermal trip
Motor overload protection has cut out due to excessive load on the turntable or carriage drive. Often occurs on heavily used machines with worn drive components.
PLC or control fault
A program logic error, low battery on the PLC, or corrupted parameter can cause the machine to stop at specific points in the cycle.
Before calling an engineer
What to check first
These are the practical checks worth trying before calling out an engineer. If none of these resolve the fault, or if the issue keeps returning, it needs a proper diagnosis.
01
Note exactly where in the cycle it stops
Count wraps or observe whether it stops during up travel, down travel, at turntable start, or at a specific height. This tells you which part of the system to investigate.
02
Read and photograph the fault code
Do not just reset — read the display and photograph any fault code showing. Even if the display is in a foreign language, the code number helps with diagnosis.
03
Check all safety guards and mats
Open and firmly close all safety guards. If there is a safety mat, step on and off it to check it resets properly. Look for any switches that feel loose or do not click cleanly.
04
Check the turntable and carriage for mechanical resistance
Manually turn the turntable by hand (with machine isolated) to feel for any unusual drag, binding or rough spots. Heavy resistance indicates a drive or mechanical issue.
When to call us
If any of these apply, call now
At this point, continued resets or workarounds are unlikely to resolve the underlying fault. A proper diagnosis is faster and cheaper than repeated call-outs for the same issue.
Fault code showing that relates to a drive, inverter or motor
Machine stops at exactly the same point in every cycle despite resets
Any smoke, burning smell or tripped circuit breaker associated with the stop
Related faults
More fault support
Report a Breakdown
Include the machine make and model, the fault you are seeing and any error codes. A photo of the display helps us triage faster.