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Disclaimer: This document is written in the hope that you can utilize for your own education to gain knowledge of PLC systems (should you decide to utilize this document). Although I believe the information in this document to be accurate, it is YOUR responsibility to verify this information before implementing it in any way, especially when damage to personnel or equipment could result. By continuing to read this document, you agree to hold no one who writes, modifies, or distributes this document liable in any way (even negligence). Due to the wide variety of plant applications, some of the examples in this document may be prohibited at your location, or could cause damage to equipment, or harm personnel.

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Troubleshooting Hardware

Ultra 3000 Drive: The status indicators and the 7 segment LED are invaluable in helping you to diagnose problems that arise with your motion system.

For the MODULE STATUS LED:

Steady Green: Normal Operation

Flashing Green: Standby Mode. The drive is not enabled

Flashing Red and Green: DC Bus UnderVoltage. This is normal operation if using auxilliary Power and main AC power is not applied, however if you are using AC power, refer to the error codes on the 7 segment display.

Flashing Red: This is a Minor Fault which can be cleared. Refer to error codes.

Solid Red: Unrecoverable fault. Contact your distributor

For the NETWORK STATUS LED:

Steady Green: Communication ready and active

Flashing Green: Establishing Communication. If the Module Status light continues to flash green, verify the node setting on the module matches the controller configuration.

Flashing Red: This indicates no communication. It could be a loose or broken fiber optic connection, or transmit/receive could be reversed on the fiber connection.

The following are error codes that may display on your Ultra3000 drive. Error codes on the drive are shown by the letter 'E' followed by a number. For more detailed information, refer to the Ultra3000 User Manual (publication 2098-IN003E-EN-P) This can be obtained by visiting www.ab.com/manuals.

Error Code	Problem
1	Non-Volatile Memory endurance exceeded. Unrecoverable Fault
2	Velocity exceeds half the Position Rollover (old drives only)
3	Absolute Feedback Range Exceeded
4	Motor Overtemperature
5	IPM Fault (Refer to user Manual)
6	Hardware Overtravel (SERCOS only)
9	Bus Undervoltage
10	Bus Overvoltage
11	Illegal Hall State (Check encoder connections and wiring)
12	Home Search Failed (Home marker outside travel limits)
13	Home Position in Limit (Home position exceeds hardware travel limits)
14	SERCOS or Devicenet hardware fault
15	Excessive electrical cycle length
16	Software Overtravel (For SERCOS drives only)
17	User-Specified current fault
18	Overspeed Fault (Exceeded 125% max rated speed)
19	Position Error limit exceeded
20	Motor Encoder state error
21	Auxilliary encoder state error
22	Motor Thermal Protection Fault
23	IPM Thermal protection fault
24	Velocity error was exceeded
25	Homing was attempted without sensor assigned
26	User specified velocity fault
27	Absolute positioning was attempted without homing
28	Parameter from encoder or controller is incompatible with the drive

Error Code	Problem
29	Encoder output frequency exceeded
30	Encoder communication fault
31	Encoder data is corrupted
32	Maximum freq. Of sine/cosine circuit has been exceeded
33	Absolute position exceeds position rollover
34	Gound Fault
35	Precharge fault (Possibly low AC input voltage)
36	Excessive heat in power circuit.
37	One or more phases of AC power have been lost
39	Motion required for startup communication was obstructed
40	230V shunt protection fault
41	460V shunt protection fault
42	The motor connected to the drive is not the motor in the program
43	The hardware enable input and software enable may be conflicting
50	Duplicate Node Fault

The 1756-MO8SE module:

The first light, CP, indicates the communication phase.

LED State	Meaning
Off	Module Not Operating
Solid Red	Phase 0 – Looking for a closed ring
Flashing Red	Phase 1 – Looking for active nodes
Alt Red/Green	Phase 2 – Configuring nodes for communication
Flashing Green	Phase 3 – Configuring Device-Specific parameters
Solid Green	Phase 4 – Configured and active

The second light is the Ring indicator:

LED State	Meaning
Solid Green	Active Ring communication
Flashing Green	The ring, drive, or axis are not configured
Flashing Red	Setup/Configuration fault
Solid Red	Hardware or installation fault
Off	No ring data has been detected

The last light is the OK indicator:

LED State	Meaning
Solid Green	Normal Operation – Data being exchanged
Flashing Green	Not communicating axis data over backplane
Flashing Red	Recoverable fault, communication fault, timer fault, or update in progress
Solid Red	Non-recoverable fault. Try cycling power to the module or replace module if problem persists
Off	The module is not operating

Motion Instructions:

For later reference, you will need to refer to this table to troubleshoot motion commands. Below is a list of the error codes you may encounter while executing a motion instruction in RSLogix 5000. More information about these errors may be found in the help menu. Click the find tab, and search for MOTION_INSTRUCTION. Then find the help file that displays the STRUCTURE of this data type.

Code	Description
.ERR	Error Codes for the .ERR member of the Motion_Instruction type
3	The instruction tried to execute again while it was still running.
4	Tried to execute command on an axis with a closed servo loop
5	Tried to execute instruction on an axis with a loop that is not closed
6	The axis drive is enabled
7	The axis is shutdown
8	Axis not configured as a servo axis
9	Instruction tried to worsen an overtravel state
10	Master axis is the same as the slave axis
11	Axis not configured
12	Messaging failed to the servo module
13	Instruction used a parameter that is outside the range limit
14	Can't apply tuning parameters due to an error in the tuning instruction
15	Cannot apply diagnostic parameters because of an error in the 'Run Diagnostic Test' instruction
16	Attempted to execute with homing in progress
17	Tried to perform a rotary move with axis not configured for rotary operation
18	Axis type is configured as unused
19	Motion group no in synchronous state – Maybe a missing servo module, or misconfiguration
20	Axis is in faulted state
21	Group is in faulted state
22	MSO or MAH attempted to execute with axis in motion
23	Attempted illegal change in dynamics

Code	Description
24	The controller was in test mode and attempted to execute one of the following: MDO MSO MAH MAJ MAM MAG MRAT or MRHD
25	The instruction is not correct
26	Length of cam array is illegal
27	Cam profile length is illegal
28	Illegal segment type in the cam element
29	Illegal order of cam elements
30	Tried to execute cam profile while already being executed
31	Tried to execute a cam profile that was already in use.
32	Cam profile array you tried to execute has not yet been calculated
33	Attempted an execution without position cam currently in progress
34	MAH trying to start with registration already running
35	Controller does not support the specified output cam
36	Cam array size not supported or a value of one of its members out of range
37	Output compensation array not supported or a member's value is out of range
38	Illegal axis data type for operation
39	Conflict in process (test and tune cannot run at the same time)
40	Drive is locally disabled while running MSO or MAH
41	Homing configuration illegal (Absolute homing instruction with homing not set to immediate.
42	Shutdown Status Timeout error code is returned when a motion instruction fails to detect the assertion of the ShutdownStatus bit within a fixed delay time period on an axis that is targeted with a shutdown. This error only indicates the status bit was not recognized. All shutdown actions have been successfully completed if this error is generated. This is most likely caused when a shutdown resiet is executed at the same time as a shutdown, thus clearing the ShutdownStatus bit before the Shutdown instruction could recognize it.

Code	Description
.STATE	Always set to 0 when the .EN bit is set.
.STATUS	Below are the possible values and descriptions for the .STATUS member
0	The message was successful.
1	Module is currently processing another message
2	Module is waiting for a response from previous message
3	Response to a message failed
4	Module not ready for messaging