Allen Bradley PowerFlex – 20P DC Drive

Allen Bradley PowerFlex – 20P DC Drive Fault Codes:

Fault Code and MeaningCause and Remedy
F4

AC Undervoltage:
There is an undervoltage on the power circuit (can only occur while the drive is active).
Cause:

  • Par 481 [UnderVolt Thresh] is set incorrectly.

  • The incoming voltage to the power terminals is too low (missing phase, poor connection).

  • The line fuses have tripped.

  • AC input voltage dips or high disturbance.

  • Fuse on overvoltage clipping board blown (frame D only).




Remedy:

  • Set Par 481 [UnderVolt Thresh] correctly and reset drive via Par 1347.

  • Verify AC input power level.

  • Check all cable connections (contactor, choke, filter).

  • Remove power, eliminate voltage dips, replace blown fuses.

  • Check/replace fuses on overvoltage clipping board.
F5

Arm Overvoltage:
There is an overvoltage on the armature circuit (125% of Par 175).
Cause:

  • Par 175 [Rated Motor Volt] is set too low.

  • Drive not configured for field weakening, but motor reaches set speed only in field weakening mode.




Remedy:

  • Set Par 175 [Rated Motor Volt] correctly.

  • Check the value of Par 469 [Field Mode Sel] and set accordingly.
F2

Auxiliary Input:
An auxiliary input interlock is open or a voltage (15…30V) is missing for digital input set to “Aux Fault”.
Cause:

  • Reference signal missing or interlock open.




Remedy:

  • Check remote wiring.

  • Note: Configure with Par 354 [Aux Inp Flt Cfg].
F64

Drive Overload:
The rated drive current was exceeded by 150% for 1 minute.
Cause:

  • Excessive load on the drive.




Remedy:

  • Reduce the drive current limits.
F132

Dsp Error:
A non-resettable software error exists on the control board.
Cause:

  • Internal control board software failure.




Remedy:

  • Cycle power to the drive.

  • If the problem persists, replace the control board.
F100

EEPROM Error:
Parameter values could not be saved or hardware config issue.
Cause:

  • Parameter values could not be saved.

  • Control board replaced and DIP switch S15 set incorrectly.

  • Major firmware revision upgrade (e.g., v2.xxx to v3.xxx).




Remedy:

  • If control board is new, verify DIP switch S15 is set correctly.

  • Reset the fault.

  • If fault occurs again, cycle power to the drive.

  • If problem persists, replace the control board.
F92

Encoder Error:
An error was detected with the Encoder signal.
Cause:

  • Issues with encoder signal or configuration.




Remedy:

  • Verify the encoder wiring.

  • Verify encoder configuration in Par 652 and DIP switches S20/S21.

  • Verify the encoder power supply.
F6

Fld Current Loss:
The field current is too low (less than 50% of Par 468).
Cause:

  • Field current regulator is not enabled.

  • Conductors in field circuit interrupted.

  • Field fuses are currently open.




Remedy:

  • Enable field current regulator via Par 497.

  • Check motor field wiring and resistance.

  • Check field fuses and replace as necessary.
F95

Fwd End Limit:
An end limit for the forward direction has been reached.
Cause:

  • Assigned contacts open due to limit reach.




Remedy:

  • If digital limits are in use, verify digital inputs are connected to normally closed contacts.
F97

Fwd Over Travel:
A forward direction over travel signal has occurred.
Cause:

  • Digital input triggered for over travel.




Remedy:

  • Verify digital input assignments (Pars 133…144).
F130

Hardware Fault:
A non-resettable hardware error has occurred.
Cause:

  • Internal hardware failure.




Remedy:

  • Cycle power to the drive.

  • If the problem persists, replace the control board.
F8

Heatsink OvrTemp:
The heatsink temperature is too high.
Cause:

  • Surrounding air temperature is too high.

  • Drive cooling fans have failed (drives > 110 A).

  • Fan fuses have failed.

  • The heatsink is dirty.




Remedy:

  • Lower the surrounding air temperature.

  • Check fan fuses and fans; replace if necessary.

  • Clean the heatsink.
F131

Interrupt Error:
A non-resettable software error in the main application.
Cause:

  • Software execution error.




Remedy:

  • Report this error to Rockwell Automation Technical Support.
F37

Inverting Fault:
A digital input configured as “Invert Flt” has been removed.
Cause:

  • Input signal lost.




Remedy:

  • Check the status of the inverting fault device connected to the digital input.
F10

Main Contactor:
Main or Dynamic Brake contactor failed to open/close in time.
Cause:

  • Contactor mechanical failure or timing issue (960ms).

  • Digital input/output wiring issue.

  • Wiring to digital input for contactor has opened.




Remedy:

  • Check all contactor wiring and drive jumpers. Repair/replace contactor.

  • Check digital input/relay output 1 wiring and configuration.
F7

Motor Overload:
The selected motor overload current level has been exceeded.
Cause:

  • Load exceeds limits based on Par 376 [MtrOvrld Type].




Remedy:

  • Reduce the motor load, current limits, and/or ramp times.
F16

Motor Over Temp:
Motor exceeded temperature rating (via thermistor).
Cause:

  • No thermistor/resistor between terminals 78 and 79.

  • Broken cable to thermistor.

  • Load cycle too extreme.

  • High surrounding temperature.

  • Fan failure (external or internal effect too low).




Remedy:

  • Check thermistor connections and cables.

  • Reduce the load.

  • Reduce surrounding air temperature.

  • Replace motor fan or fit external fan.
F0

No Fault / Info:
Information only or HIM display issue.
Cause:

  • If on HIM: SA-SB terminal on frame B/C incorrectly configured or control power issue.




Remedy:

  • Informational only.

  • For Frame B/C: Verify terminal SA-SB configuration for control circuit input power.
F89

Open SCR:
An open SCR fault condition has been detected.
Cause:

  • Open SCR detected during diagnostic test.




Remedy:

  • Verify correct values in Pars 217 and 218.

  • Replace the failed SCR devices.
F13

Overcurrent:
An overcurrent occurred in the motor circuit.
Cause:

  • Short-circuit or ground fault at output.

  • Current regulator not properly fine-tuned.

  • Par 584 [OverCurrent Thr] value too low.




Remedy:

  • Verify armature circuit wiring.

  • Tune the Current Regulator (see manual).

  • Increase the value of Par 584 accordingly.
F25

Overspeed:
Speed feedback indicated speed > Par 585 [Overspeed Val].
Cause:

  • Excessive load or overhauling conditions.

  • Threshold too low.




Remedy:

  • Remove excessive load or overhauling conditions.

  • Increase value of Par 585 [Overspeed Val].
F48

Params Defaulted:
User parameters reset to default values.
Cause:

  • System reset or corruption.




Remedy:

  • Informational only.
F71…75

Port 1…5 Adapter:
The communication card has a fault.
Cause:

  • Communication card error.




Remedy:

  • Check the DPI device event queue and fault information for the device.
F81…85

Port 1…5 DPI Loss:
The DPI port stopped communicating.
Cause:

  • Disconnected cable or adapter.

  • Intentional disconnect without masking bit.




Remedy:

  • Check HIM connection and wiring.

  • Replace wiring, port expander, or control board if required.

  • If intentional, set appropriate bit in Par 591 [Logic Mask] to “0”.
F3

Power Failure:
Fault in 24V control board supply or incoming voltage low.
Cause:

  • Problem with external I/O wiring (short circuit).

  • Blown fuses (F1, F2, F3) on switching power supply or pulse transformer.

  • AC input voltage too low or poor connections.




Remedy:

  • Check I/O wiring for shorts/shielding issues.

  • Check and replace fuses F1, F2, F3 as necessary.

  • Verify AC input power level and connections.
F93

Resolver Error:
An error was detected with the resolver signal.
Cause:

  • Signal loss or configuration error.




Remedy:

  • Verify resolver wiring.

  • Verify resolver configuration in Pars 423, 424, and 425.

  • Verify resolver power supply.
F96

Rev End Limit:
Reverse end limit reached.
Cause:

  • Contacts open due to limit reach.




Remedy:

  • If digital limits used, verify digital inputs connected to normally closed contacts.
F98

Rev Over Travel:
Reverse direction over travel signal occurred.
Cause:

  • Digital input triggered.




Remedy:

  • Verify digital input assignments.
F90

Shorted SCR:
Shorted SCR fault condition detected.
Cause:

  • Failed SCR device.




Remedy:

  • Replace failed SCR device or devices.
F91

Spd Fdbk Loss:
Speed feedback lost or inconsistent with armature voltage.
Cause:

  • Feedback signal conductors interrupted.

  • Encoder/resolver channels missing (no power).

  • Motor voltage incorrect.

  • Ramp rate too fast for load.

  • Field Weakening set incorrectly.

  • Encoder/resolver config incorrect.




Remedy:

  • Check feedback device wiring and power supply.

  • Verify Par 175 and tune motor.

  • Reduce load or ramp rate.

  • Verify Par 456 [Fld Weaken Ratio].

  • Verify encoder/resolver DIP switches and params (Par 652, 426).
F20

SSC Error:
Valid fiber packet not received within time period.
Cause:

  • Fiber-optic connection issue.

  • Damaged cables.




Remedy:

  • Verify fiber-optic connections are secure.

  • Check cables for damage; replace if necessary.

  • If persists, replace Fiber-optic Interface circuit board.
F62

STune Aborted:
Speed regulator auto tuning stopped manually.
Cause:

  • User stopped the process.




Remedy:

  • Informational only.
F59

STune CurLimit:
Auto tuning current limit too high or speed zero levels high.
Cause:

  • Par 1048 [Autotune Cur Lim] too high.

  • Par 107/108 set too high.




Remedy:

  • Decrease value of Par 1048 and repeat tune.

  • Set Pars 107 and 108 to default values.
F60

STune FrictionLo:
Friction value attained during tune is zero or too low.
Cause:

  • Control precision limit issue.




Remedy:

  • Decrease value of Par 1048 [Autotune Cur Lim] and repeat.
F58

STune LoadHi:
Loading torque too high at zero speed.
Cause:

  • Load torque too high.

  • Par 107/108 set too high.




Remedy:

  • Decrease load torque and repeat.

  • Set Pars 107 and 108 to defaults.
F56

STune Overspeed:
Measured motor speed too high during tuning.
Cause:

  • Current limit excessive for load.




Remedy:

  • Decrease value of Par 1048 [Autotune Cur Lim] and repeat.
F57

STune Stalled:
Drive stalled during speed regulator tuning.
Cause:

  • Current limit too low to move motor.




Remedy:

  • Increase value of Par 1048 [Autotune Cur Lim] and repeat.
F61

STune Timeout:
Auto tuning did not complete within 15 minutes.
Cause:

  • Par 1048 too low.

  • Max speed parameters (Par 45, 3, 4) set incorrectly for test.




Remedy:

  • Verify value of Par 1048.

  • Set max speed parameters appropriately (must reach 33%).

  • Repeat tuning procedure.
F70

Sustained Curr:
Motor CEMF too high or current bridge change failed.
Cause:

  • Motor CEMF too high or line voltage too low.

  • Current bridge change command not completed within 1 second.




Remedy:

  • Check line voltage and frequency.

  • Check motor brushes and connections.

  • Check main and DB contactor connections.

  • Verify no overhauling loads present.
F94

TorqPrv Spd Band:
Speed deviation exceeded level in Par 1105.
Cause:

  • Speed loop tuning not correct.

  • Drive operating under current limit.

  • Accel/Decel rates too fast.

  • Brake not releasing.

  • Motor field not reaching rated value.

  • Drive undersized.




Remedy:

  • Increase Par 434 or Par 433.

  • Raise current limit (Par 7).

  • Reduce accel/decel rates.

  • Check brake wiring/operation.

  • Check motor field wiring/config.

  • Reduce the load.
F99

Travel Lim Cflct:
Travel limits are in conflict (Forward and Reverse active simultaneously).
Cause:

  • Digital limits: Both inputs off simultaneously (e.g., loss of common power).

  • Software limits: Bits in Par 1101 set incorrectly simultaneously.




Remedy:

  • Verify wiring of digital limit switches (normally closed).

  • Check state of fwd/rev travel limit bits in Par 1101.
Arm Overvoltage
Type 1
Cause: There is a possible overvoltage on the armature circuit or Par 175 [Rated Motor Volt] is set too low for the application.



Remedy: See the “Arm Overvoltage” fault description in the manual (page 222) for more information.
Auxiliary Input
Type 1
Cause: An auxiliary input interlock is open or a voltage (15…30V) or reference signal is missing for the digital input set to 14 “Aux Fault”.



Remedy: See the “Auxiliary Input” fault description in the manual (page 222) for more information.
BipolarCflct
Type 2
Cause: Par 1322 [Direction Mode] is set to “Bipolar” or “Reverse Dis” and one or more of these digital input functions is configured: “Fwd/Reverse,” “Run Forward,” “Run Reverse,” “Jog Forward,” “Jog Reverse,” “Rev Dec Limit,” or “Rev End Limit.”



Remedy: Check parameter configurations and ensure digital input functions match the Direction Mode setting.
BrakeSlipped
Type 1 & 2
Cause: The encoder movement has exceeded the level in Par 1110 [Brk Slip Count] after the brake was set.

  • Type 1: The brake slip maneuver is controlling the drive (drive is active).

  • Type 2: The brake slip maneuver is finished (drive is stopped).





Remedy: Cycle power to the drive to reset.
CntactrCflct
Type 2
Cause: Contactor input functions are in conflict.

  • When [ContactorControl] is “None”, relay outputs/digital inputs cannot be set to “Contactor” or “ContactorDB”.

  • When [ContactorControl] is “AC Cntcr” or “DC Cntcr”, one relay output and one digital input must be set to “Contactor”.

  • When [ContactorControl] is “AC Cntcr+DB” or “DC Cntcr+DB”, relays and inputs must be set to “Contactor” and “ContactorDB” respectively.





Remedy: Program the parameter selections so that they match the relay output and/or digital input terminal block wiring correctly.
DigInCflctA
Type 2
Cause: Digital input functions are in conflict. Combinations of the following settings cause an alarm:

  • Acc2/Dec2 vs Accel 2, Decel 2

  • Jog 1/2 vs Jog Fwd, Jog Rev

  • Fwd/Rev vs Jog Fwd, Jog Rev





Remedy: Check digital input assignments and remove conflicting combinations.
DigInCflctB
Type 2
Cause: One of these digital input conflicts exists:

  • A digital Start input has been configured without a Stop input.

  • None of the digital inputs are configured for “Enable”.

  • Other digital input functions are in conflict (e.g., Run vs Run Fwd/Rev, Jog vs Run).





Remedy: Configure a Stop input, ensure Enable is configured, and resolve function conflicts.
DigInCflctC
Type 2
Cause: Multiple physical inputs have been configured to the same input function. Duplicate configurations are not allowed for:

  • Forward/Reverse, Run Reverse, Run Forward

  • Jog Forward, Jog Reverse, Speed Select (1, 2, 3)

  • Acc2 / Dec2, Accel 2, Decel 2, Run





Remedy: Remove duplicate input configurations.
FB Cfg Cflct
Type 2
Cause: Feedback configuration conflict has occurred:

  • [Fdbk Device Type] is not “Armature” but [Spd Loss Flt Cfg] is “Alarm” and [SpdReg FB Bypass] is “Disabled”.

  • [Fdbk Device Type] is “Resolver” but other parameters are selecting a resolver signal incorrectly.

  • [Fdbk Device Type] is “Encoder” but other parameters are selecting an encoder signal incorrectly.





Remedy: Correct the [Fdbk Device Type] or the associated source selection parameters (Pars 429, 430, 786, 1021, 1204, 1284).
FldCfg Cflct
Type 2
Cause: The selected operating mode of the field controller is in conflict with another setting, or a permanent magnet motor is incorrectly configured.

  • Conflict between Field Mode Sel (Weakened/External) and Feedback Device (Armature).

  • Conflict between Field Mode Sel and Speed Loss Fault Config.

  • Conflict between Field Mode Sel (Base Speed) and Field Reg Enable (Disabled).

  • Conflict between Field Mode Sel and Force Min Field settings.





Remedy: Review parameters 469, 414, 478, 497, 498, and Digital Inx Sel for consistency.
Fld Current Loss
Type 1
Cause: The field current is too low.



Remedy: See the “Fld Current Loss” fault description in the manual (page 222) for more information.
Motor Overload
Type 1
Cause: The selected motor overload current level has been exceeded.



Remedy: See the “Motor Overload” fault description in the manual (page 223) for more information.
Motor Over Temp
Type 1
Cause: The motor has exceeded its temperature rating (as signaled by the thermistor connected to drive terminals 78 and 79).



Remedy: See the “Motor Over Temp” fault description in the manual (page 223) for more information.
Ref Cflct
Type 2
Cause: Reference Conflict:

  • Multiple drive reference inputs are set to the same value (Pars 70, 75, 80, 1323-1327, 1021, 430, 1375).

  • Both [Resolver Pos Sel] and [Resolver Spd Sel] are non-zero.

  • Multiple source parameters (PID Source, Line Spd Source, Ref Spd Source) contain the same value.





Remedy: Change the parameter selections so that unique sources are defined for the reference inputs.
Open SCR
Type 1
Cause: An open SCR condition has been detected (Par 213 bit 0 set and Par 216 set to “Alarm”).



Remedy: See the “Open SCR” fault description in the manual (page 89) for more information.
Spd Fdbk Err
Type 1
Cause: With Par 478 [Spd Loss Flt Cfg] set to 1 “Alarm”, an error condition associated with the selected speed feedback device (analog tachometer, encoder, or resolver) was detected.



Remedy: Check the speed feedback device connections and operation.
Spd Fdbk Loss
Type 1
Cause: Par 478 set to “Alarm”. The speed feedback device indicates a value less than 5% of Max Feedback Spd, but the measured armature voltage is greater than the value of Par 455 [Spd FB Loss Lvl].



Remedy: See the “Spd Fdbk Loss” fault description in the manual (page 225) for more information.
Start At PowerUp
Type 1
Cause: Par 1344 [Start At Powerup] is enabled.



Remedy: The drive can start at any time after power-up and the specified delay (Par 1345). Disable Par 1344 if this behavior is not desired.
Torq Prov Cflct
Type 2
Cause: Par 1100 [Torq Prove Cfg] is enabled, but a conflict exists:

  • Operating non-regenerative drive (negative current required).

  • Direction Mode set to “Rev Disable”.

  • Feedback Device set to “Armature Voltage” or “DC Tach” (with Encoderless=0).

  • Speed Loop or Field configurations incorrect (e.g., SpdReg FB Bypass enabled).

  • Digital Input “Lift Stop” missing or TP Enable bit 0 is 0.

  • Alpha Test On or TstGen Output connected.





Remedy: Check Par 1100, 1322, 414, 458, 457, 166, 58, 467, 498, 245, and 241 settings. Ensure relay outputs are not defined as “TP Brake Cmd” if not intended.
TP Encls Config
Type 2
Cause: The drive has been configured to enable Encoderless TorqProve, but an application conflict exists.



Remedy: You must read and understand the “Attention” on page 309 relating to the use of TorqProve with no encoder before you can continue.