ACOPOS 1016 Ready LED Blinking on a New Fixture Despite Using the Same Configuration

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Hello everyone,

I am facing an issue with a new fixture using a B&R motion control system. I would appreciate your suggestions on troubleshooting this issue.

Hardware configuration

  • B&R X20 PLC

  • ACOPOS 1016 servo drive

  • 8AC114.60-2 POWERLINK module

  • 8AC123.60-1 encoder module

Problem description

We have a new fixture that replicates an existing, working fixture. Both fixtures use the same motor, servo drive model, encoder, addon modules, and source code.

However, on the new fixture, the ACOPOS 1016 READY LED keeps blinking, and the motor does not start. We checked the possible causes listed in the user manual and verified the wiring against the existing working fixture.

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Initially, we suspected a faulty servo drive or addon module. We replaced the drive and addon modules with spare units, but the problem remained.

Troubleshooting performed

  1. Checked the wiring against the old, working fixture.

  2. Verified that the POWERLINK node number is correct.

Replaced the drive and addon modules with spare units(new one), but the issue persisted.

  1. Installed the servo drive and addon modules from the old working fixture into the new fixture. The motor started rotating successfully.

This is confusing because the new fixture works with the servo drive and addon modules taken from the old fixture, but not with the recently purchased

units, despite using the same source code and verified wiring.

Questions

  1. Could this issue be related to ACOPOS firmware or operating-system compatibility with the X20 PLC or Automation Studio project?

  2. Are there any hardware revision or firmware compatibility requirements for the ACOPOS 1016 and 8AC114.60-2 POWERLINK module?

  3. Could a drive parameter or configuration mismatch prevent the replacement drive from becoming ready, even when the POWERLINK node number is correct?

  4. What diagnostic information should I check in Automation Studio to identify the root cause?

  5. Is there any recommended procedure for commissioning or replacing an ACOPOS drive and its addon modules in an existing project?

Any suggestions or troubleshooting steps would be appreciated.

Thank you.