Troubleshooting / PowerFlex 70 and 700 faults

PowerFlex 70 and 700 Fault Codes

The fault and alarm codes of the Allen-Bradley PowerFlex 70 and PowerFlex 700 drives: what each number means, the likely causes, the first checks with the parameters to look at, and how to log it so it stops coming back.

How faults and alarms show

When the drive trips, the STS light flashes red (steady red means a non-resettable fault). An LCD HIM shows Faulted in the status line with the fault number, the fault name and the time since the fault, for example F 5 OverVoltage; press Esc to get HIM control back. A PowerFlex 70 LED HIM shows only the fault code.

An alarm does not trip the drive by itself: the STS light turns yellow, an LCD HIM shows a bell and, for type 2 alarms, the alarm name; read type 1 alarms in [Drive Alarm 1] (211) and start inhibits in [Start Inhibits] (214).

The fault queue is in parameters 243 to 250 on the PowerFlex 70 ([Fault 1 Code] to [Fault 4 Code], each with its time) and 243 to 258 on the PowerFlex 700 (8 faults). Fault 1 is the newest. To clear a fault, fix the cause, then press Stop, cycle power, set [Fault Clear] (240) to 1 or pick Clear Faults in the HIM Diagnostics menu; 240 set to 2 clears the queue.

Type 1 faults reset and restart on their own when [Auto Rstrt Tries] (174) is above 0, after [Auto Rstrt Delay] (175), as long as the drive stays in Run; a Stop aborts the restart, and fault 33 shows when the tries run out. Alarms clear themselves when the condition goes away.

Safety first.
Rockwell says to verify that the DC bus capacitors have discharged before any work on the drive, and that only qualified personnel may install, start up or maintain it. On the PowerFlex 70, measure between the +DC terminal of the power terminal block and the -DC test point. On the PowerFlex 700 Frames 0 to 6 (and 7 to 10), measure +DC to -DC, +DC to chassis and -DC to chassis.

Every reading must be zero. The general warnings give no fixed wait time, so always measure; the PowerFlex 700 Frames 7 to 10 instructions tell you to remove all input power and wait 5 minutes for the bus to discharge before checking the blower.

Sources: PowerFlex 70 User Manual 20A-UM001P and Installation Instructions 20A-IN009G, PowerFlex 700 User Manual 20B-UM002H and Installation Instructions 20B-IN019G and 20B-IN014H. Follow lockout/tagout and your site's safe-work procedures, and check the manual for your exact model before you act.

Quick lookup

Faults trip the drive and stop the machine, so in OEE they are availability losses; alarms let the drive keep running until you act.

Type a number or a word (ground fault, overvoltage, heatsink, port 5) to filter the list. Click a code for its causes and first checks.

69 codes

CodeTypePowerFlexName
2Fault70 and 700Auxiliary Input
3Fault70 and 700Power Loss
4Fault70 and 700UnderVoltage
5Fault70 and 700OverVoltage
7Fault70 and 700Motor Overload
8Fault70 and 700Heatsink OvrTemp
9Fault70 and 700Trnsistr OvrTemp
10Fault70 and 700Heatsink LowTemp
12Fault70 and 700HW OverCurrent
13Fault70 and 700Ground Fault
15Fault70 and 700Load Loss
16Fault70 and 700Motor Thermistor
17Fault70 and 700Input Phase Loss
18Fault700Hardware PTC
20Fault700TorqPrv Spd Band
21Fault700Output PhaseLoss
24Fault70 and 700Decel Inhibit
25Fault70 and 700OverSpeed Limit
29Fault70 and 700Analog In Loss
33Fault70 and 700Auto Rstrt Tries
36Fault70 and 700SW OverCurrent
38Fault70 and 700Phase U to Grnd
39Fault70 and 700Phase V to Grnd
40Fault70 and 700Phase W to Grnd
41Fault70 and 700Phase UV Short
42Fault70 and 700Phase VW Short
43Fault70 and 700Phase UW Short
48Fault70 and 700Params Defaulted
49Fault70 and 700Drive Powerup
52Fault70 and 700Faults Cleared
55Fault70 and 700Cntl Bd Overtemp
63Fault70 and 700Shear Pin
64Fault70 and 700Drive OverLoad
69Fault70 and 700DB Resistance
70Fault70 and 700Power Unit
75Fault70 and 700Port 5 Adapter
77Fault70 and 700IR Volts Range
78Fault70 and 700FluxAmpsRef Rang
79Fault70 and 700Excessive Load
80Fault70 and 700AutoTune Aborted
81Fault70 and 700Port 1 DPI Loss
82Fault70 and 700Port 2 DPI Loss
85Fault70 and 700Port 5 DPI Loss
87Fault70 and 700IXo VoltageRange
88Fault700Software Fault
90Fault70 and 700Encoder Quad Err
91Fault70 and 700Encoder Loss
92Fault700Pulse In Loss
93Fault70 and 700Hardware Fault
100Fault70 and 700Parameter Chksum
101Fault70 and 700UserSet1 Chksum
106Fault70 and 700Incompat MCB-PB
107Fault70 and 700Replaced MCB-PB
108Fault70 and 700Anlg Cal Chksum
111Fault70Enable Hardware
111Fault700Power Down Csum
112Fault70Power Down Csum
121Fault700I/O Comm Loss
122Fault700I/O Failure
900Fault70 and 700Fatal Faults
2Alarm70 and 700UnderVoltage
3Alarm70 and 700Power Loss
4Alarm70 and 700Start At PowerUp
8Alarm70 and 700Drive OL Level 1
9Alarm70 and 700Drive OL Level 2
10Alarm70 and 700Decel Inhibit
13Alarm70 and 700In Phase Loss
15Alarm70 and 700Ground Warn
18Alarm70 and 700Dig In ConflictB

Each code: causes and first checks

2: Auxiliary Input

Hits OEE: Availability

What it means: An external interlock wired to a digital input set as Aux Fault has opened, so the drive trips at once and stays faulted until it is reset.[1][2][3]

Likely causes

  • External interlock, permissive or overload contact opened
  • Broken or loose wire on the Aux Fault input
  • Digital input set to Aux Fault by mistake

First checks, in this order

  1. Find the input set to Aux Fault in [Digital In1 Sel] to [Digital In6 Sel] (361 to 366) and check its state in [Dig In Status] (216).
  2. Check the remote device and the wiring that feeds that input.
  3. Close the circuit, then clear the fault; closing the input alone does not restart the drive.

3: Power Loss

Hits OEE: Availability

What it means: DC bus voltage stayed below the power loss level for longer than [Power Loss Time] (185); the PowerFlex 700 manuals give the level as 85% of nominal. It trips only when enabled in [Fault Config 1] (238); the same event also exists as alarm 3.[1][2][3]

Likely causes

  • Input power dip or short interruption
  • Upstream contactor, breaker or fuse opening
  • Weak supply sagging when large loads start

First checks, in this order

  1. Monitor the incoming AC line for low voltage or interruptions.
  2. Check [Power Loss Mode] (184) and [Power Loss Time] (185).
  3. Check [DC Bus Memory] (13), the running average the drive uses to detect a power loss.
  4. Enable or disable the fault in [Fault Config 1] (238).

4: UnderVoltage

Hits OEE: Availability

What it means: DC bus voltage fell below the minimum. PowerFlex 700: 407 V DC on 400/480 V drives, 204 V DC on 200/240 V drives. PowerFlex 70 Standard Control: 509, 407 or 204 V DC for 600, 400/480 and 200/240 V input; Enhanced Control: 375, 300 or 160 V DC.[1][2][3]

Likely causes

  • Low incoming line voltage
  • Power interruption or brownout
  • Missing phase or loose input connection

First checks, in this order

  1. Measure the incoming AC voltage on all three phases.
  2. Watch [DC Bus Voltage] (12) while the problem happens.
  3. Enable or disable this fault in [Fault Config 1] (238).

5: OverVoltage

Hits OEE: Availability

What it means: DC bus voltage went above its maximum, usually because the motor fed energy back during a fast stop or an overhauling load, or because the line voltage is high or spiky.[1][2][3]

Likely causes

  • Deceleration time too short for the load inertia
  • Overhauling load, such as lowering, unwinding or a fan turned by draft
  • High line voltage or transients
  • Bus regulation off and no brake resistor fitted

First checks, in this order

  1. Monitor the AC line for high voltage or transients.
  2. Extend [Decel Time 1] (142).
  3. Check the bus regulator setting [Bus Reg Mode A] (161).
  4. Fit a dynamic brake resistor if the load regenerates, and set [DB Resistor Type] (163).

7: Motor Overload

Hits OEE: Availability

What it means: The drive's electronic motor overload tripped: output current stayed above the motor rating set in [Motor NP FLA] (42) for too long.[1][2][3]

Likely causes

  • Mechanical overload, jam or binding
  • Wrong motor nameplate current entered
  • Motor too small for the duty
  • High flux braking level (PowerFlex 70)

First checks, in this order

  1. Reduce the load so output current stays at or below [Motor NP FLA] (42).
  2. Check [Motor NP FLA] (42), [Motor OL Hertz] (47) and [Motor OL Factor] (48) against the motor nameplate.
  3. Watch [Motor OL Count] (220) to see how close the motor runs to a trip.
  4. PowerFlex 70: if flux braking is on, check [Flux Braking %] (549).
  5. Enable or disable the fault in [Fault Config 1] (238).

8: Heatsink OvrTemp

Hits OEE: Availability

What it means: Heatsink temperature went over 100% of the drive temperature rating shown in [Drive Temp] (218). On PowerFlex 700 Vector Control 4.001 and later the same fault also covers a heatsink colder than about -19 °C.[1][2][3]

Likely causes

  • Ambient temperature above the drive rating
  • Heatsink fan stopped or weak
  • Dirty or blocked heatsink fins or cabinet filters
  • Excess load
  • Very cold ambient (PowerFlex 700 Vector Control)

First checks, in this order

  1. Check that the maximum ambient temperature has not been exceeded.
  2. Check that the fan runs and that air flows freely through the heatsink.
  3. Check for excess load.
  4. Read the heatsink temperature: set [Testpoint 1 Sel] (234) to 2 and read [Testpoint 1 Data] (235).
  5. In cold rooms, add space heaters.

9: Trnsistr OvrTemp

Hits OEE: Availability

What it means: The output transistors (IGBTs) went over their maximum operating temperature.[1][2][3]

Likely causes

  • High ambient temperature
  • Fan problem or blocked air flow
  • Excess load

First checks, in this order

  1. Check that the maximum ambient temperature has not been exceeded.
  2. Check the fan.
  3. Check for excess load and look at [Drive OL Count] (219).

10: Heatsink LowTemp

Hits OEE: Availability

What it means: The heatsink reads too cold, or the heatsink temperature sensor (NTC) circuit is open. On the PowerFlex 700 it is listed for Vector Control firmware 6.002 and later.[1][3]

Likely causes

  • Very cold ambient
  • Open or loose NTC sensor connection

First checks, in this order

  1. Check the ambient temperature.
  2. In cold locations, add space heaters.
  3. Check the connections to the NTC sensor (PowerFlex 70 action list).

12: HW OverCurrent

Hits OEE: Availability

What it means: Output current went above the hardware current limit, the fastest and hardest current trip.[1][2][3]

Likely causes

  • Short in the output wiring or motor
  • Excess load or a jam
  • Boost or DC brake voltage set too high
  • Wrong programming

First checks, in this order

  1. With power locked out, check the drive output wiring and the motor for shorts.
  2. Check for excess load.
  3. Check the boost and DC brake voltage settings and the rest of the programming.

13: Ground Fault

Hits OEE: Availability

What it means: Current is flowing to earth ground at more than 25% of the drive rating.[1][2][3]

Likely causes

  • Damaged motor cable insulation
  • Motor winding shorted to frame
  • Water, oil or dust in the motor terminal box
  • Wiring error on the drive output

First checks, in this order

  1. Lock out power, then check the motor and the output wiring to the drive terminals for a grounded condition.
  2. Disconnect the motor leads from the drive and insulation test the motor and cable.
  3. Set [Gnd Warn Level] (177) so alarm 15 Ground Warn warns before the drive trips.

15: Load Loss

Hits OEE: Availability

What it means: Output torque current stayed below [Load Loss Level] (187) for longer than [Load Loss Time] (188), as happens when a belt, chain or coupling breaks. PowerFlex 70: Enhanced Control firmware 2.001 and later.[1][2][3]

Likely causes

  • Broken belt, chain or coupling
  • Pump running dry or empty conveyor
  • Load loss level or time set too tight

First checks, in this order

  1. Check the mechanical connection between motor and load.
  2. Check [Load Loss Level] (187) and [Load Loss Time] (188) against the real process.
  3. Enable or disable the fault in [Fault Config 1] (238).

16: Motor Thermistor

Hits OEE: Availability

What it means: The motor thermistor signal is out of range: the motor is hot or the thermistor is not connected. PowerFlex 70: Enhanced Control only; the analog input must read between 0.2 V and 5.0 V.[1][2][3]

Likely causes

  • Motor overheated
  • Thermistor disconnected or wire broken
  • Analog input set up wrong for the thermistor

First checks, in this order

  1. Check that the thermistor is connected.
  2. If the motor is hot, reduce the load and check motor cooling.
  3. Check the Motor Therm bit (bit 7) in [Fault Config 1] (238) or [Alarm Config 1] (259).

17: Input Phase Loss

Hits OEE: Availability

What it means: DC bus ripple went over a preset level, which usually means an incoming phase is missing. PowerFlex 70: Enhanced Control firmware 2.001 and later.[1][2][3]

Likely causes

  • Blown input fuse
  • Open phase in the supply, disconnect or contactor
  • Badly unbalanced supply

First checks, in this order

  1. Check the incoming power for a missing phase or blown fuse.
  2. Measure all three input voltages under load.
  3. PowerFlex 700: the fault is switched on by bit 8 In PhaseLoss of [Fault Config 1] (238), on by default only for Frames 8 to 10.

18: Hardware PTC

Hits OEE: Availability

What it means: The motor PTC (positive temperature coefficient) sensor reports overtemperature.[3]

Likely causes

  • Motor too hot
  • PTC sensor wiring open

First checks, in this order

  1. Check motor temperature, load and cooling.
  2. Check the PTC wiring from the motor to the drive.
  3. Check the PTC HW bit in [Fault Config 1] (238).

20: TorqPrv Spd Band

Hits OEE: Availability

What it means: With TorqProve (crane and hoist logic), the difference between [Commanded Speed] and [Encoder Speed] stayed above [Spd Dev Band] (602) for longer than [Spd Band Integrat].[2][3]

Likely causes

  • Mechanical brake not releasing
  • Wiring problem between drive and motor
  • Encoder feedback problem

First checks, in this order

  1. Check the wiring between drive and motor.
  2. Check that the mechanical brake releases.
  3. Check the encoder and its wiring.

21: Output PhaseLoss

Hits OEE: Availability

What it means: Current in one or more output phases has been lost or stays below a preset level.[2][3]

Likely causes

  • Disconnected or broken motor lead
  • Open output contactor or disconnect contact
  • Open motor winding

First checks, in this order

  1. Check the drive and motor wiring.
  2. Check phase to phase continuity at the motor terminals.
  3. Look for disconnected motor leads. When TorqProve is enabled this check always runs.

24: Decel Inhibit

Hits OEE: Availability

What it means: The drive is not following the commanded deceleration because the bus regulator is holding back to limit DC bus voltage, and the drive stopped decelerating altogether.[1][2][3][5]

Likely causes

  • Input voltage too high
  • Regenerating or high inertia load with a short decel time
  • Poor system grounding
  • No brake resistor on a regenerating load

First checks, in this order

  1. Check that input voltage is within the drive limits.
  2. Check that system ground impedance follows proper grounding practice.
  3. Extend [Decel Time 1] (142), add a dynamic brake resistor, or turn off the adjust freq part of bus regulation in [Bus Reg Mode A] (161) and [Bus Reg Mode B] (162).
  4. Enable or disable the fault in [Fault Config 1] (238).

25: OverSpeed Limit

Hits OEE: Availability

What it means: Slip compensation or bus regulation tried to push output frequency past [Maximum Speed] (82) plus [Overspeed Limit] (83).[1][2][3][5][6]

Likely causes

  • Overhauling load driving the motor
  • Fast rise in supply voltage (more than 10% within 6 minutes) while the bus regulator adjusts frequency
  • Overspeed limit set too low

First checks, in this order

  1. Remove excessive load or overhauling conditions.
  2. Increase [Overspeed Limit] (83), keeping [Maximum Speed] plus [Overspeed Limit] at or below [Maximum Freq] (55).
  3. Keep supply voltage within the drive rating, or turn off the adjust freq part of bus regulation (161, 162).

29: Analog In Loss

Hits OEE: Availability

What it means: An analog input set to fault on signal loss has lost its signal, for example a 4 to 20 mA loop that opened.[1][2][3]

Likely causes

  • Broken or loose wire at the analog input
  • Transmitter or signal source off or failed
  • Loss setting picked by mistake

First checks, in this order

  1. Check the analog input loss settings ([Anlg In 1 Loss] is 324 on the PowerFlex 70).
  2. Check for broken or loose connections at the inputs.
  3. Measure the signal at the drive terminals with a meter.

33: Auto Rstrt Tries

Hits OEE: Availability

What it means: The drive tried to reset a fault and restart the set number of times ([Auto Rstrt Tries], 174) and failed each time.[1][2][3]

Likely causes

  • A fault that keeps coming back, such as power loss or overvoltage
  • Root cause not fixed

First checks, in this order

  1. Read the fault queue ([Fault 1 Code] 243 onward) to find the fault that kept returning.
  2. Correct that cause, then clear the fault by hand.
  3. Check [Auto Rstrt Tries] (174) and [Auto Rstrt Delay] (175); enable or disable this fault in [Fault Config 1] (238).

36: SW OverCurrent

Hits OEE: Availability

What it means: Output current went over the drive's 1 ms rating, typically 200 to 250% of the continuous rating: above the 3 second rating but below the hardware trip.[1][2][3]

Likely causes

  • Excess load or shock load
  • Boost set too high
  • DC brake voltage set too high
  • Acceleration too fast for the load

First checks, in this order

  1. Check for excess load.
  2. Check the boost and DC brake voltage settings.
  3. Extend [Accel Time 1] (140) if it trips while speeding up.
  4. PowerFlex 70: if flux braking is on, check [Flux Braking %] (549).

38: Phase U to Grnd

Hits OEE: Availability

What it means: A phase to ground fault was found between the drive and the motor on phase U.[1][2][3]

Likely causes

  • Damaged insulation on the U lead
  • Motor winding grounded on phase U
  • Failed drive output

First checks, in this order

  1. Check the wiring between drive and motor.
  2. Check the motor for a grounded phase.
  3. If motor and cable test good, the drive may need replacing.

39: Phase V to Grnd

Hits OEE: Availability

What it means: A phase to ground fault was found between the drive and the motor on phase V.[1][2][3]

Likely causes

  • Damaged insulation on the V lead
  • Motor winding grounded on phase V
  • Failed drive output

First checks, in this order

  1. Check the wiring between drive and motor.
  2. Check the motor for a grounded phase.
  3. If motor and cable test good, the drive may need replacing.

40: Phase W to Grnd

Hits OEE: Availability

What it means: A phase to ground fault was found between the drive and the motor on phase W.[1][2][3]

Likely causes

  • Damaged insulation on the W lead
  • Motor winding grounded on phase W
  • Failed drive output

First checks, in this order

  1. Check the wiring between drive and motor.
  2. Check the motor for a grounded phase.
  3. If motor and cable test good, the drive may need replacing.

41: Phase UV Short

Hits OEE: Availability

What it means: Excessive current was detected between output terminals U and V.[1][2][3]

Likely causes

  • Short between the U and V motor leads
  • Shorted motor winding
  • Failed drive output

First checks, in this order

  1. Check the motor and the drive output terminal wiring for a short.
  2. If wiring and motor are good, the drive may need replacing.

42: Phase VW Short

Hits OEE: Availability

What it means: Excessive current was detected between output terminals V and W.[1][2][3]

Likely causes

  • Short between the V and W motor leads
  • Shorted motor winding
  • Failed drive output

First checks, in this order

  1. Check the motor and the drive output terminal wiring for a short.
  2. If wiring and motor are good, the drive may need replacing.

43: Phase UW Short

Hits OEE: Availability

What it means: Excessive current was detected between output terminals U and W.[1][2][3]

Likely causes

  • Short between the U and W motor leads
  • Shorted motor winding
  • Failed drive output

First checks, in this order

  1. Check the motor and the drive output terminal wiring for a short.
  2. If wiring and motor are good, the drive may need replacing.

48: Params Defaulted

Hits OEE: Availability

What it means: The drive was told to write factory default values to its memory, so your settings are gone.[1][2][3]

Likely causes

  • Someone ran a reset to defaults
  • Defaults loaded during service or a board change

First checks, in this order

  1. Clear the fault or cycle power.
  2. Program the drive parameters again, or restore them from your saved backup.

49: Drive Powerup

Hits OEE: Availability

What it means: Not a real trip: a power up marker written to the fault queue to show that drive power was cycled. PowerFlex 70: Enhanced Control firmware 2.001 and later.[1][2][3]

Likely causes

  • Drive power was switched off and on

First checks, in this order

  1. Use it as a timeline marker when reading the fault queue (243 onward).

52: Faults Cleared

Hits OEE: Availability

What it means: Not a real trip: a marker in the fault queue showing that a fault clear was done. PowerFlex 70: Enhanced Control firmware 2.001 and later.[1][2][3]

Likely causes

  • A fault was cleared with Stop, [Fault Clear] (240) or the HIM

First checks, in this order

  1. Read the entries below it in the queue to see which fault was cleared.

55: Cntl Bd Overtemp

Hits OEE: Availability

What it means: The temperature sensor on the main control board found too much heat.[1][2][3]

Likely causes

  • Control board fan stopped
  • Hot cabinet or poor ventilation
  • Drive mounted without proper clearance

First checks, in this order

  1. Check the main control board fan.
  2. Check the surrounding air temperature.
  3. Check mounting clearances and cabinet cooling.

63: Shear Pin

Hits OEE: Availability

What it means: Output current went over the programmed [Current Lmt Val] (148) with the shear pin fault turned on, used to protect machinery from a jam.[1][2][3]

Likely causes

  • Jam or sudden mechanical overload
  • Current limit set too low for normal load peaks

First checks, in this order

  1. Check the load and the machine for a jam.
  2. Check [Current Lmt Val] (148).
  3. In [Fault Config 1] (238) you can ignore the shear pin during accel and decel (ShearPNoAcc bit).

64: Drive OverLoad

Hits OEE: Availability

What it means: The drive's own rating of 110% for 1 minute or 150% for 3 seconds was exceeded.[1][2][3]

Likely causes

  • Load heavier than the drive rating
  • Acceleration too fast
  • Drive undersized for the motor or duty

First checks, in this order

  1. Reduce the load or extend [Accel Time 1] (140).
  2. Watch alarms 8 and 9 (Drive OL Level 1 and 2) and [Drive OL Count] (219), which warn before this trip.
  3. Check [Drive OL Mode] (150).

69: DB Resistance

Hits OEE: Availability

What it means: The resistance of the internal dynamic brake resistor is out of range.[1][2][3]

Likely causes

  • Failed or open internal brake resistor
  • Wrong brake resistor setting

First checks, in this order

  1. Replace the resistor.
  2. Check that [DB Resistor Type] (163) matches the resistor actually fitted.

70: Power Unit

Hits OEE: Availability

What it means: One or more output transistors ran in the active region instead of fully on (desaturation), caused by too much transistor current or too little gate drive voltage.[1][2][3]

Likely causes

  • Damaged output transistors
  • Short or very heavy current on the output
  • Gate drive problem in the power section

First checks, in this order

  1. Check for damaged output transistors.
  2. Check the motor and cable for shorts before powering again.
  3. If it repeats, replace the drive.

75: Port 5 Adapter

Hits OEE: Availability

What it means: The communications adapter in DPI port 5, the internal network card such as a 20-COMM-E EtherNet/IP adapter, reported a fault to the drive. Rockwell lists it in the range 71 to 75, Port 1 to 5 Adapter.[1][2][3][4]

Likely causes

  • Network I/O connection lost (cable, switch, IP address conflict) while the adapter is set to fault the drive on comm loss, which is the default
  • PLC put in Program mode or faulted while the adapter is set to fault the drive on idle
  • Adapter hardware or setup problem

First checks, in this order

  1. On the HIM, select the Port 5 device (the adapter) and read its event queue for the exact cause.
  2. Check the network cable, switch port, IP address and the MOD and NET A lights.
  3. Check that the PLC is in Run and the I/O connection to the drive is healthy.
  4. Review the adapter's [Comm Flt Action] and [Idle Flt Action] (parameters 21 and 22 on a 20-COMM-E).

77: IR Volts Range

Hits OEE: Availability

What it means: Autotune is on Calculate (the default) and the IR Drop Volts value it worked out is outside the acceptable range.[1][2][3]

Likely causes

  • Wrong or missing motor nameplate data

First checks, in this order

  1. Re-enter the motor nameplate data, then autotune again.

78: FluxAmpsRef Rang

Hits OEE: Availability

What it means: The flux current measured by autotune is higher than the programmed motor current [Motor NP FLA] (42).[1][2][3]

Likely causes

  • Wrong motor nameplate current entered
  • Motor and drive data do not match

First checks, in this order

  1. Set [Motor NP FLA] (42) to the correct nameplate value.
  2. Repeat the autotune.

79: Excessive Load

Hits OEE: Availability

What it means: During autotune the motor did not reach speed in the time allowed.[1][2][3]

Likely causes

  • Load still coupled during a rotate tune
  • Brake applied or machine binding

First checks, in this order

  1. Uncouple the load from the motor.
  2. Repeat the autotune.

80: AutoTune Aborted

Hits OEE: Availability

What it means: The autotune was cancelled by the user or stopped by another fault.[1][2][3]

Likely causes

  • Stop pressed during autotune
  • Another fault during the tune

First checks, in this order

  1. Fix any other fault shown, then restart the autotune.

81: Port 1 DPI Loss

Hits OEE: Availability

What it means: DPI port 1, the HIM mounted in the drive cover, stopped talking to the drive. Rockwell lists it in the range 81 to 85, Port 1 to 5 DPI Loss.[1][2][3]

Likely causes

  • HIM pulled out without using the Remove function
  • HIM removed while in Manual mode or while it was the only control device
  • Loose or damaged HIM connection

First checks, in this order

  1. Reseat the HIM and check its connection.
  2. To remove a HIM without a fault, use ALT then Remove, in Auto mode only.
  3. If the HIM is meant to stay off, set its bit in [Logic Mask] (276) to 0.

82: Port 2 DPI Loss

Hits OEE: Availability

What it means: DPI port 2, the cable port for a handheld or remote HIM or other DPI device, stopped talking to the drive.[1][2][3]

Likely causes

  • Remote HIM or converter unplugged
  • Damaged DPI cable or splitter
  • SCANport device on a drive running DPI at 500k baud

First checks, in this order

  1. Check the cable, splitter and device on port 2.
  2. Replace the cable or device if damaged.
  3. If the device was removed on purpose, set its bit in [Logic Mask] (276) to 0.

85: Port 5 DPI Loss

Hits OEE: Availability

What it means: DPI port 5, where the internal communications adapter connects, stopped talking to the drive over DPI.[1][2][3]

Likely causes

  • Adapter ribbon cable loose or unplugged
  • Failed communications adapter
  • Adapter removed while its [Logic Mask] bit is still set

First checks, in this order

  1. Check that the adapter is seated and its DPI cable is connected.
  2. Replace the cable or the adapter if needed.
  3. If the adapter was removed on purpose, set its bit in [Logic Mask] (276) to 0.

87: IXo VoltageRange

Hits OEE: Availability

What it means: The voltage calculated for the motor's inductive impedance is more than 25% of [Motor NP Volts] (41). PowerFlex 70: Enhanced Control firmware 2.001 and later.[1][2][3]

Likely causes

  • Motor much smaller or larger than the drive
  • Wrong motor voltage entered

First checks, in this order

  1. Check that the motor is sized correctly for the drive.
  2. Check [Motor NP Volts] (41).
  3. Extra output impedance may be needed.

88: Software Fault

Hits OEE: Availability

What it means: Microprocessor handshake error on the main control board. Fault 89 has the same name and meaning.[2][3]

Likely causes

  • Main control board fault

First checks, in this order

  1. Cycle power once to see if it returns.
  2. Replace the main control board.

90: Encoder Quad Err

Hits OEE: Availability

What it means: Both encoder channels changed state within one clock cycle, which points to electrical noise or a bad encoder.[1][2][3]

Likely causes

  • Electrical noise on the encoder cable
  • Poor shield or ground
  • Failing encoder

First checks, in this order

  1. Check for externally induced noise: cable routing away from motor leads, shield grounding.
  2. Replace the encoder.

91: Encoder Loss

Hits OEE: Availability

What it means: One or both encoder channel signals are missing. The PowerFlex 700 needs a differential encoder for this check. PowerFlex 70: Enhanced Control firmware 2.001 and later.[1][2][3]

Likely causes

  • Broken or loose encoder wire
  • Encoder power missing
  • Failed encoder

First checks, in this order

  1. Check the encoder wiring.
  2. Check motor rotation and the encoder pulses (PowerFlex 700).
  3. Check [Motor Fdbk Type] (412) and [Encoder PPR] (413).
  4. Replace the encoder.

92: Pulse In Loss

Hits OEE: Availability

What it means: The Z channel is set up as a pulse input but its signal is missing.[2][3]

Likely causes

  • Broken pulse input wire
  • Failed pulse generator

First checks, in this order

  1. Check the wiring.
  2. Replace the pulse generator.

93: Hardware Fault

Hits OEE: Availability

What it means: Hardware enable is disabled (jumpered high) but the logic pin still reads low.[1][2][3]

Likely causes

  • Enable jumper missing or wrong
  • Main control board fault

First checks, in this order

  1. Check the hardware enable jumper.
  2. Replace the main control board.

100: Parameter Chksum

Hits OEE: Availability

What it means: The parameter checksum read from the board does not match the calculated one, so stored settings may be corrupt.[1][2][3]

Likely causes

  • Corrupt parameter memory
  • Power lost while parameters were being saved

First checks, in this order

  1. Restore defaults.
  2. Reload the user set, if one is used, or reprogram the drive.

101: UserSet1 Chksum

Hits OEE: Availability

What it means: The checksum of saved user set 1 does not match. Faults 102 (UserSet2 Chksum) and 103 (UserSet3 Chksum) mean the same for user sets 2 and 3.[1][2][3]

Likely causes

  • Corrupt saved user set

First checks, in this order

  1. Save the user set again.

106: Incompat MCB-PB

Hits OEE: Availability

What it means: Drive rating data stored on the power board is not compatible with the main control board. The PowerFlex 70 fault table spells it Incompact MCB-PB.[1][2][3]

Likely causes

  • Control board or power board swapped from another drive
  • Firmware too old for the power section

First checks, in this order

  1. Load compatible firmware into the drive.
  2. PowerFlex 700 Frames 7 to 10 need firmware 4.009 or later.

107: Replaced MCB-PB

Hits OEE: Availability

What it means: The main control board was replaced and the parameters have not been programmed.[1][2][3]

Likely causes

  • New or spare control board fitted

First checks, in this order

  1. Restore defaults.
  2. Reprogram the parameters from your saved backup.

108: Anlg Cal Chksum

Hits OEE: Availability

What it means: The checksum of the analog input calibration data does not match the calculated one.[1][2][3]

Likely causes

  • Corrupt factory calibration data

First checks, in this order

  1. Replace the drive.

111: Enable Hardware

Hits OEE: Availability

What it means: PowerFlex 70 Enhanced Control: the hardware enable circuit is wrong. Either the Safe-Off board is missing and pins 3 and 4 of the Safe-Off connector are not jumpered, or the board is fitted but the enable jumper was left in.[1]

Likely causes

  • Safe-Off board not installed and pins 3 and 4 not jumpered
  • Safe-Off board installed but enable jumper still on the main control board
  • Failed Safe-Off board or hardware enable circuit

First checks, in this order

  1. Without a Safe-Off board, install the board or jumper pins 3 and 4.
  2. With a Safe-Off board, find and remove the enable jumper on the main control board.
  3. Replace the Safe-Off board or the control board if the fault stays.

111: Power Down Csum

Hits OEE: Availability

What it means: PowerFlex 700 Vector Control firmware 6.002 and later: memory (EEPROM) data was found corrupt at power up. The PowerFlex 70 uses fault 112 for this.[3]

Likely causes

  • Power removed while data was being saved
  • Memory fault on the control board

First checks, in this order

  1. Clear the fault or cycle power.
  2. Check your parameter settings afterwards.

112: Power Down Csum

Hits OEE: Availability

What it means: Memory (EEPROM) data was found corrupt at power up.[1]

Likely causes

  • Power removed while data was being saved
  • Memory fault on the control board

First checks, in this order

  1. Clear the fault or cycle power.
  2. Check your parameter settings afterwards.

121: I/O Comm Loss

Hits OEE: Availability

What it means: The I/O board lost communication with the main control board.[2][3]

Likely causes

  • Loose I/O board connector
  • Electrical noise
  • Failed I/O board or main control board

First checks, in this order

  1. Check the connector between the I/O board and the control board.
  2. Check for induced noise.
  3. Replace the I/O board or the main control board.

122: I/O Failure

Hits OEE: Availability

What it means: The I/O board was detected but failed its power up sequence. The I/O board is separate on Standard Control and built into the control board on Vector Control.[2][3]

Likely causes

  • Failed I/O board (Standard Control)
  • Failed main control board (Vector Control)

First checks, in this order

  1. Standard Control: replace the I/O board.
  2. Vector Control: replace the main control board.

900: Fatal Faults

Hits OEE: Availability

What it means: Codes 900 to 930 are diagnostic codes for an internal drive malfunction.[1][3]

Likely causes

  • Main control board failure
  • Internal firmware or hardware error

First checks, in this order

  1. Cycle power.
  2. Replace the main control board if it returns.
  3. Contact Rockwell technical support with the exact code.

2: UnderVoltage

Warning: act before it becomes a stop

What it means: Alarm 2 (not fault 2): the DC bus voltage has dropped below a set level. If it keeps falling the drive can trip on fault 4.[1][2][3]

Likely causes

  • Low or sagging line voltage
  • Input power interruption

First checks, in this order

  1. Measure the incoming line voltage.
  2. Watch [DC Bus Voltage] (12).
  3. Turn the alarm on or off in [Alarm Config 1] (259).

3: Power Loss

Warning: act before it becomes a stop

What it means: Alarm 3: the drive has sensed a power line loss. With [Fault Config 1] (238) set for it, the drive trips on fault 3 after [Power Loss Time] (185).[1][2][3]

Likely causes

  • Short line dip or outage
  • Upstream breaker or contactor opening

First checks, in this order

  1. Monitor the incoming AC line.
  2. Check [Power Loss Mode] (184) and [Power Loss Time] (185).
  3. Turn the alarm on or off in [Alarm Config 1] (259).

4: Start At PowerUp

Warning: act before it becomes a stop

What it means: Alarm 4: [Start At PowerUp] is enabled, so the drive can start the motor at any time within 10 seconds of power up. Keep clear of the machine.[1][2][3]

Likely causes

  • Start at power up turned on for automatic restart after outages

First checks, in this order

  1. Confirm this setting is intended and safe for the machine.
  2. Turn off [Start At PowerUp] if an automatic start is not wanted.

8: Drive OL Level 1

Warning: act before it becomes a stop

What it means: Alarm 8: the calculated IGBT temperature calls for a lower PWM frequency. If [Drive OL Mode] (150) is disabled and the load stays high, the drive will trip on overload.[1][2][3]

Likely causes

  • Load near or above the drive rating
  • High PWM frequency with heavy load
  • Hot ambient

First checks, in this order

  1. Reduce the load or improve cooling.
  2. Check [Drive OL Mode] (150) and [PWM Frequency] (151).
  3. Watch [Drive OL Count] (219).

9: Drive OL Level 2

Warning: act before it becomes a stop

What it means: Alarm 9: the calculated IGBT temperature calls for a lower current limit. If [Drive OL Mode] (150) is disabled and the load stays high, the drive will trip on overload.[1][2][3]

Likely causes

  • Sustained load above the drive rating
  • Hot ambient or poor cooling

First checks, in this order

  1. Reduce the load.
  2. Check [Drive OL Mode] (150).
  3. Check that the drive is sized for the duty.

10: Decel Inhibit

Warning: act before it becomes a stop

What it means: Alarm 10: the drive is being held back from decelerating, usually by the bus regulator limiting DC bus voltage. The PowerFlex 700 tables spell it Decel Inhibt. If decel stops completely, fault 24 follows.[1][2][3]

Likely causes

  • Decel time too short for a high inertia or regenerating load
  • High line voltage

First checks, in this order

  1. Extend [Decel Time 1] (142).
  2. Add a dynamic brake resistor if the load regenerates.
  3. Check [Bus Reg Mode A] (161).

13: In Phase Loss

Warning: act before it becomes a stop

What it means: Alarm 13 (not fault 13 Ground Fault): DC bus ripple has gone over the phase loss level, a sign of a missing or weak input phase.[1][2][3]

Likely causes

  • Blown input fuse
  • Unbalanced or weak supply phase

First checks, in this order

  1. Check the input fuses and all three line voltages.
  2. Fix it before it becomes fault 17 Input Phase Loss.

15: Ground Warn

Warning: act before it becomes a stop

What it means: Alarm 15: ground current has passed the level set in [Gnd Warn Level] (177). It is an early warning of a developing ground fault.[1][2][3]

Likely causes

  • Insulation breaking down in the motor or cable
  • Moisture in the motor or terminal box

First checks, in this order

  1. Plan an insulation test of the motor and cable at the next stop.
  2. Check [Gnd Warn Level] (177).

18: Dig In ConflictB

Warning: act before it becomes a stop

What it means: Alarm 18: a digital Start input is set up without a Stop input, or other input functions conflict. The drive will not start; the STS light flashes yellow and the LCD HIM shows DigIn CflctB.[1][2][3]

Likely causes

  • Start configured but Stop not configured or not wired
  • Mixed 2 wire and 3 wire input settings

First checks, in this order

  1. Check [Digital In1 Sel] to [Digital In6 Sel] (361 to 366) and remove conflicting choices.
  2. Wire and configure a Stop input when using 3 wire Start.
  3. Check [Drive Status 2] (210) for active type 2 alarms.

Log it, or the same alarm comes back

A fault trips the drive and stops the motor, so in OEE terms it is a breakdown. An alarm lets the drive keep running or blocks the next start, and its cause often becomes a fault later in the shift. Log faults with the minutes lost and alarms as early signs.

  • Reason code: the fault number plus the drive, for example PowerFlex 700 F13, mixer agitator drive, so a ground fault that comes back after every washdown shows up as a pattern.
  • Loss bucket: a stop that needs a reset, a part or a technician is an availability loss (breakdown). Stops shorter than your micro-stop threshold go to performance (minor stops). The six big losses page shows where each one belongs.
  • What to count: how often each code fires per week and the minutes it costs. Two numbers a week turn "that alarm comes up sometimes" into a ranked list. The MTBF and MTTR calculator and the downtime cost calculator do the math.

The free OEE tracker logs each stop with its reason and turns the week into a downtime Pareto, so the code that costs the most rises to the top.

For the PowerFlex 525, fabrico.io has the PowerFlex 525 fault codes guide. A fault code tells you what the drive measured, not what happened at the machine in the seconds before. Fabrico's camera-based OEE software syncs line camera video with machine data, so you can replay the moment the line stopped next to the trip.

Frequently asked questions

What is fault 75 on a PowerFlex 70?

Fault 75 is Port 5 Adapter. DPI port 5 is where the internal communications adapter plugs in, for example a 20-COMM-E EtherNet/IP card, so the fault means that adapter reported a problem to the drive. A common trigger is a lost network I/O connection or a PLC switched to Program mode, because by default the adapter's Comm Flt Action and Idle Flt Action (parameters 21 and 22 on the 20-COMM-E) fault the drive. Check the network cable and switch, the adapter lights and the PLC mode, then select the Port 5 device on the HIM and read its event queue for the exact cause. The number means the same on a PowerFlex 700.

How do I clear a fault on a PowerFlex 700?

Press Esc to acknowledge the fault, fix the cause, then clear it by pressing Stop, cycling power, setting parameter 240 [Fault Clear] to 1, or choosing Clear Faults in the HIM Diagnostics menu. Non-resettable (type 2) faults need the repair first and reset at power up. If 241 [Fault Clear Mode] is set to Disabled, reset attempts are blocked. To let type 1 faults reset themselves, set [Auto Rstrt Tries] (174) and [Auto Rstrt Delay] (175), keeping in mind the motor will then restart on its own.

What does Heatsink OvrTemp mean on a PowerFlex 70?

Fault 8, Heatsink OvrTemp, means the heatsink got hotter than 100% of the drive's rated temperature, which you can watch in [Drive Temp] (218). Check the room or cabinet temperature against the drive rating, make sure the heatsink fan runs, clean blocked fins and filters, and look for excess load. To read the actual heatsink temperature, set [Testpoint 1 Sel] (234) to 2 and read [Testpoint 1 Data] (235). The related fault 9, Trnsistr OvrTemp, means the output transistors themselves are too hot.

Where do I find the fault codes and fault history on a PowerFlex 70 or 700?

The active fault shows on the LCD HIM as a number and a name, for example F 13 Ground Fault, with the time since it happened. The fault queue keeps past trips: on the PowerFlex 70 in parameters 243 to 250 (Fault 1 to 4 Code and Time) and on the PowerFlex 700 in 243 to 258 (Fault 1 to 8). Fault 1 is the newest. Entries 49 Drive Powerup and 52 Faults Cleared are markers, not trips. Common codes are 2 Auxiliary Input, 3 Power Loss, 4 UnderVoltage, 5 OverVoltage, 7 Motor Overload, 8 Heatsink OvrTemp, 12 HW OverCurrent, 13 Ground Fault, 24 Decel Inhibit and 64 Drive OverLoad.

What is fault 13 on a PowerFlex 700?

Fault 13 is Ground Fault: current is flowing to earth ground at more than 25% of the drive rating. Lock out the drive, confirm the DC bus reads zero, then check the motor and the output wiring for a grounded condition, and insulation test the motor and cable with the leads disconnected from the drive. Do not confuse it with alarm 13, In Phase Loss, which is an input supply warning. To get an early warning next time, set [Gnd Warn Level] (177) so alarm 15 Ground Warn shows before the drive trips.

Sources

Codes and meanings follow the manufacturer documentation below. Wording is ours, simplified for the shop floor; the manual for your exact model and software version wins if it differs.

  1. PowerFlex 70 Adjustable Frequency AC Drives User Manual (Standard Control firmware 2.xxx, Enhanced Control firmware 2.xxx to 5.xxx), publication 20A-UM001P-EN-P, February 2018
  2. PowerFlex 700 AC Drives Series A, Frames 0 to 6 User Manual (Standard Control firmware 3.001 and below, Vector Control firmware 3.002 and below), publication 20B-UM001H-EN-P, June 2013
  3. PowerFlex 700 AC Drives Frames 0 to 10 User Manual (Vector Control firmware 4.001 and up), publication 20B-UM002H-EN-P, December 2022
  4. 20-COMM-E EtherNet/IP Adapter User Manual (Series A FRN 2.xxx, Series B FRN 4.xxx), publication 20COMM-UM010H-EN-P, July 2015
  5. PowerFlex 70 Adjustable Frequency AC Drive Installation Instructions, publication 20A-IN009G-EN-P, April 2022
  6. PowerFlex 700 Adjustable Frequency AC Drive Frames 0 to 6 Installation Instructions, publication 20B-IN019G-EN-P, September 2023

See the moment the drive tripped

Fabrico, a light MES with computer vision, syncs camera footage with machine and timeline data, so you can replay the exact moment the line stopped and review the cause next to the drive's fault. Cameras also catch short stops and a line that is switched on but not producing, the losses nobody writes down. Machines connect through a PLC, a Fabrico IoT device or an AI camera.

Book a Fabrico demo
The lookup stays free.

Related: PowerFlex 753 and 755 fault codes · 1336 and 1305 fault codes · SEW-Eurodrive fault codes · VFD drive troubleshooting · electric motor

Other alarm code lookups: FANUC: servo amplifier · spindle amplifier · robot SRVO | Siemens: MICROMASTER 440 · MASTERDRIVES · SINAMICS G120 · SINAMICS V90 servo · SINAMICS V20 | ABB: ACS550 drive · ACS800 drive · robot IRC5 | Okuma: OSP alarms | Haas: alarm lookup | Mitsubishi: MELSERVO servo · FR-D700 and FR-E700 inverters · FX PLC | Allen-Bradley: Kinetix and Ultra3000 · MicroLogix · PowerFlex 753 and 755 · 1336 and 1305 | Yaskawa: V1000 drive · SERVOPACK servo · Motoman robot | Delta: VFD drives · ASDA servo | Eaton: DC1 and SVX9000 drives | Control Techniques: Commander SK and M200 | Kollmorgen: AKD servo | Lenze: SMVector, 8200, 8400, i500 | Magnetek: IMPULSE and DSD 412 | Omron: MX2 and RX inverters · G5 and 1S servo | WEG: CFW500, CFW300, CFW11, CFW08 | Hitachi: WJ200 inverter | Toshiba: E3, Q9, P9, S15, nC3, AS3 | AutomationDirect: GS10, GS20, GS4, GS1 to GS3 | SANYO DENKI: SANMOTION servo | Parker: SSD 590+, 690+, AC10 | KEB: COMBIVERT F5 | Epson: robot RC700, RC90 | B&R: ACOPOS servo | Schneider Electric: Lexium 32 servo | Bosch Rexroth: IndraDrive | Vacon: NX, VACON 100 and 20 | Fuji Electric: FRENIC-Mini, Multi, Ace, MEGA | LS Electric: S100, G100, iG5A | Panasonic: MINAS A6 and A5 servo | Invertek: Optidrive E3, P2, Eco | SEW-Eurodrive: MOVITRAC B and MOVIDRIVE B

Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary

OEE essentials: OEE calculator · What is OEE · How to improve OEE · Six big losses · Availability · TEEP · Cost of downtime · OEE benchmark · Free OEE tracker · Free OEE software · How to track downtime · How to implement OEE · Light MES vs full MES