Red Lion G3 and AB Ultra3000

We recently replaced a Quartech 2800 on a press feeder with a 6" G3. Right now it is just being used to read/write index distances and velocities of an AB Ultra 3000 drive. The possibilities seem endless with the G3 and so I wanted to play around with this type of setup and see what we can do in the future as we have several more feeders that are prime candidates for this type of upgrade. First, I would like to add a page to display any drive faults, but I am having trouble reading data that makes any sense to me. For example, I currently have a 2098-DSDHV-150X in my office with no motor attached, therefore the drive shows fault 04 (Motor Overtemp). I verified, using the drive software, that this is the only active fault. I put a data box on the screen that is read only and is assigned to a data tag with the the source CO74(0), which is Fault Status when picking from the available drive information. My tag is setup with no manipulation and to treat the data as an integer. What I read in my box is (8). I tried all of the tag manipulation choices, but I just got results that confused me further. I have read through the PDF from Red Lion about the Ultra 3000 driver and also Rockwell's Ultra 3000 Host Commands for Serial Communication, I think page 222 holds the answer but I'm not sure. I am still confused about what types of data I should be seeing from the drive.

I apologize, when I wrote page 222 of the Host Command for Serial Communication PDF may contain the answer, it should have read 2-122 or page number 138.

When a fault occurs in the drive, it sets a specific bit in the fault integer rather than just changing its value. The advantage of this is that multiple faults can be indicated simultaneously. So, what you're seeing is correct. When a motor thermostat error occurs it sets bit 3 in the fault word. The binary value of 1000 is equal to 8 in decimal, which is what the Red Lion displays by default. In the Properties for the data box in Crimson, you can change the display mode to Binary, then you'll be able to see the individual bits.

P.S. I've used the Red Lion / Ultra 3000 combination on a number of projects and I can assure you that the driver is very reliable.

Thank you! I will try this out on Monday.

I was able to see the correct bit coming on by displaying the data in a binary format in my data box. How did you display multiple faults? I have created a tag assigned to the Servo Fault Status tag and then made the format multi-state. I made the value of each state represent a specific fault or multiple faults, for example if bits 1 and 2 are on, my value is 6 and my description would say that faults two and three are on.
My other question is that I want to start sending information between the PLC and the drive. I set up a couple of gateway blocks using different data types and assigned them to the same Servo Fault Status tag. I could get the correct information in once, but then I would not see it update. I have the update rate for the block set to continuous. Note that I have now attached a motor to my drive so that I can clear the fault to see the state change. I am attached to a Micrologix 1500 via a Net-ENI. I am attaching my Crimson program. Would someone please steer me the correct direction on this?

https://www.dropbox.com/s/v1czrbp8ks89yw5/500T%20Feeder_2_18_15_Test.cd3?dl=0

Thank You

Displaying multiple faults is tricky. You can't really do this with a Multi-State indicator because the Data value you specify for each state represents the entire integer value, not individual bits. So, if the fault word contains 32 bits and we assume that any combination of them could be on simultaneously (not true of course but it would be tough to determine which combinations are valid/possible), you'd need 2^32 or 4,294,967,296 individual messages.

The best way to catch multiple faults with the G3 is probably to assign each fault bit to its own tag, and use the Alarm functionality in Crimson. So:
1. You need a numeric tag that contains the whole fault word, which you already have named "Fault_Status". Make it an unsigned integer.
2. Create 32 flag tags that represent the individual faults. The source of each tag will be "Fault_Status.x" where x is the bit number. (I'd suggest putting them in a folder.)
3. For each of the flag tags, configure a Data Match alarm in the Alarms tab with the appropriate message and a Value of true. Trigger should be level triggered and Accept automatic.
4. Put an alarm viewer primitive somewhere on your display. Now you'll see notification when any of the individual bits go high.

Thank you Kolyur for the information! The unit is in production and the maintenance and production employees like it so much they want the other pieces of similar equipment changed over to G3s. I spoke with a specialist from Red Lion about the issues I was having getting information from some of the Ultra 3000 driver tags, specifically any that do not have an adjustable element, he said this was not the intended behavior and that their software team would work to correct it.

Thanks for the feedback. I'm glad it's working out well for you.