E22 and E24 on Ultra 3000 with DeviceNet, Logix5555

[VernonAzuki 0]

We are pulling our hair out trying to figure out this issue. We have an AB MPL-A330P-HK22AA servo motor that started randomly throwing E22 and E24 errors on us about 6 months ago. Very hit or miss - sometimes none in a day other times more. We are now at the point where the drive will often not even home on the packaging machine. It also throws these faults before the drive even starts moving (or as it does). The shaft/gearbox it's driving moves easily by hand when the machine is e-stopped and was recently refurbished with new shafts/bearings while troubleshooting the issue. If we can get it to run we will get 20-30 cycles before it faults out. Here is everything we've done throughout the troubleshooting process as it got worse and worse to no avail:

We tried another MPL-A330P-HK22AA. We swapped the feedback cable with a new one. We switched to a MPL-A330P-HK72AA with new power and feedback cables. We installed a factory new Ultra 3000. Cables were rerouted so they did not run near other power cables or supplies. Any ideas? The only cable we have not swapped is the CN1 that runs from the Ultra 3000 to the PLC but the tech does not think this could possibly be the cause and doesn't feel qualified to mess with it or the connections.

Servo motor is driving sealing jaws for a Wolf packaging machine - Logix5555 on DeviceNet and the Ultra 3000 is a 2098-DSD-030. I found a post here on the forum from Folivar describing a similar issue about 10 years ago but he did not follow up what the fix was. :-/