Tag: Troubleshooting Guide

Introduction

As an industrial engineer, I know those blinking lights on your VersaMax CPU matter. They tell you what’s wrong. Learn to read them and fix problems fast.

Understanding Your CPU’s Status Lights

Each light color and pattern means something different:

• GREEN RUN light (steady): CPU working normally
• GREEN RUN light (blinking): Minor issue – check soon
• RED STOP light (steady): CPU stopped – could be on purpose or from error
• RED STOP light (blinking): Serious problem – fix now
• YELLOW I/O FORCED light: Some points are manually controlled – make sure this is intentional
• RED FAULT light (steady): Major error – CPU likely stopped
• RED FAULT light (blinking): Smaller error – needs checking
• COMM light (green): Network working well
• COMM light (yellow/red): Network problems – check connections

Expert tip: Watch light combinations. Blinking RUN + steady FAULT means something different than just a FAULT light.

Fast Troubleshooting Steps

When lights show trouble:

1. Stay calm & note lights: Write down which lights are on/off/blinking
2. Check basics first:
   • Is power connected?
   • Are cables loose?
   • Any physical damage?
3. Connect software: Use Proficy Machine Edition for error codes
4. Fix based on lights:
   • I/O FORCED: Unforce points in software
   • FAULT: Check for program errors or hardware mismatches
   • COMM: Inspect network cables and IP settings
5. Safe restart: Power cycle if safe for your process
6. Check manual: Look up specific error codes

Key approach: Fix simple things first. Move to complex checks only if needed.

Prevent Future Problems

• Backup programs: Save copies regularly
• Control cabinet environment: Keep clean, cool and dry
• Update firmware: Install latest versions
• Replace old parts: Plan for aging components
• Add diagnostic routines: Catch issues early

Understanding these lights saves time and keeps production running.

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