Allen-Bradley PLC Major Fault — Motion Axis Fault (Type 06)

ControlLogix motion axis has faulted. Servo drive reported a critical error through the motion module (1756-M02AE, 1756-M03SE, Kinetix). Axis motion stopped.

Probable Causes (ranked)

• Servo drive reported overcurrent, overvoltage, or ground fault
• Motor feedback (encoder/resolver) cable disconnected or damaged
• Physical obstruction preventing axis from following commanded motion profile
• Motion module lost connection to the Kinetix servo drive on SERCOS or CIP Motion bus
• Axis hard limit switch tripped — axis reached physical end of travel
• Motor brake not releasing — brake power supply issue

Fix Steps

1. 1 In RSLogix 5000, check the axis properties — Faults tab shows the specific motion fault code
2. 2 Check Kinetix drive display for fault code — cross-reference with Kinetix user manual
3. 3 Inspect motor encoder/resolver cable at both motor and drive ends — reseat connectors
4. 4 Check for mechanical obstruction — with drive disabled, try to move axis by hand
5. 5 If CIP Motion bus error, check Ethernet cable between motion module and Kinetix drive
6. 6 Clear axis fault using MSF (Motion Servo Off) then MSO (Motion Servo On) instructions in logic
7. 7 Home the axis after clearing the fault before resuming automatic motion

Suggested Replacement Parts

Parts matched to fault category: Servo Drive

Prices are estimates. Verify part numbers match your equipment before ordering.

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