Troubleshooting / PowerFlex 750 faults

PowerFlex 753 and 755 Fault Codes

The fault and alarm codes of Allen-Bradley PowerFlex 753 and 755 drives: what each number means, which ones you can configure, the likely causes, the first checks in order, and how to log it so the same stop stops coming back.

How PowerFlex 750 drives show faults

When a fault trips the drive, the 20-HIM-A6 or 20-HIM-C6S shows a flashing pop-up with the fault number, its text and the time since it happened, and P951 [Last Fault Code] keeps the first fault since the last reset.

In the HIM DIAGNOSTIC folder for Port 00, Faults lists the last 32 trips with time stamps (01 is the newest) and Alarms lists the alarm history, while active type 1 alarms show in P959 [Alarm Status A] and P960 [Alarm Status B] and type 2 alarms in P961 [Type 2 Alarms]. A fault stops the drive, a type 1 alarm is a configurable warning that lets a running drive keep running but stops a restart, and a type 2 alarm is a setup conflict that blocks starting until the parameters are fixed.

After fixing the cause, clear a fault with the CLR soft key or Stop key on the HIM, a digital input assigned in P156 [DI Clear Fault], the Clear Fault bit in the logic command word from the PLC, or a power cycle, and note that clearing a fault does not empty the fault queue.

Option modules show the port number in front of the event (4001 is event 1 on port 4, 14037 is event 37 on port 14). Auto restart is set with P348 [Auto Rstrt Tries] (0 to 9) and P349 [Auto Rstrt Delay], works only for faults marked Auto Reset that occur while running, and ends in fault 33 AuRsts Exhausted when the tries run out.

Safety first.
Rockwell says to verify that the bus capacitors have fully discharged before servicing: on Frames 1 to 7 measure between +DC and -DC and from each terminal to chassis, and all three readings must be zero, while on Frames 8 to 10 you measure at the DC+ and DC- TESTPOINT sockets on the front of the power module.

For PowerFlex 755 Frame 8 and larger, the hardware service manual says to lock out all input power including any regenerative or other DC source, wait 15 minutes and confirm no voltage at the input terminals before measuring the bus.

Only qualified personnel should do this work, and Rockwell cautions that auto restart (P348) and start at power up (P345) let the drive issue its own start command. Follow lockout/tagout and your site's safe-work procedures, and check the manual for your exact model before you act.

Quick lookup

Faults stop the drive and the motor, so in OEE they are availability losses; type 1 and type 2 alarms let the drive keep running or only block the next start. Several faults can be set to alarm or ignore by parameter.

Type a number or a word (ground fault, overvoltage, overload, DPI) to filter the list. Click a number for its causes and first checks.

60 codes

CodeTypeName
2FaultAuxiliary Input
3AlarmPower Loss
4FaultUnderVoltage
5FaultOverVoltage
7FaultMotor Overload
8FaultHeatsink OvrTemp
9FaultTrnsistr OvrTemp
10AlarmDynBrake OvrTemp
12FaultHW OverCurrent
13FaultGround Fault
14AlarmGround Warning
15FaultLoad Loss
17FaultInput Phase Loss
18FaultMotor PTC Trip
19AlarmTask Overrun
20FaultTorqPrv Spd Band
21FaultOutput PhaseLoss
24FaultDecel Inhibit
25FaultOverSpeed Limit
26AlarmBrake Slipped
29FaultAnalog In Loss
33FaultAuRsts Exhausted
34FaultAutClrFltExhaust
35FaultIPM OverCurrent
36FaultSW OverCurrent
38FaultPhase U to Grnd
39FaultPhase V to Grnd
40FaultPhase W to Grnd
41FaultPhase UV Short
42FaultPhase VW Short
43FaultPhase WU Short
48FaultSystem Defaulted
55FaultCtrl Bd Overtemp
59FaultInvalid Code
61FaultShear Pin 1
62FaultShear Pin 2
64FaultDrive OverLoad
71FaultPort 1 Adapter
79FaultExcessive Load
80FaultAutoTune Aborted
81FaultPort 1 DPI Loss
82FaultPort 2 DPI Loss
91FaultPriVelFdbk Loss
100FaultParameter Chksum
106FaultIncompat MCB-PB
107FaultReplaced MCB-PB
111FaultPwrBd Invalid ID
138FaultPrecharge Open
152FaultNo Stop Source
157AlarmDigIn Cfg B
168FaultHeatSinkUnderTmp
169AlarmPWM Freq Reduced
170AlarmCurLimit Reduced
210FaultHW Enbl Jmpr Out
211FaultSafety Brd Fault
212FaultSafety Jmpr Out
213FaultSafety Jumper In
224FaultPort 4 Comm Loss
315FaultExcess Psn Err
322AlarmN-1 Operation

Each code: causes and first checks

Fault 2: Auxiliary Input

Hits OEE: Availability

What it means: A digital input set up as an auxiliary fault interlock has opened, so the drive will not power the motor. Something in the machine wired to that input is withholding permission to run.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, auto restart and auto clear allowed, input set in P157. 755T: shown as code 1 Auxiliary Input (755T code 2 is Sys Default Fail). PowerFlex 525: F002 Auxiliary Input has the same meaning.

Likely causes

  • The device wired to the input assigned in P157 [DI Aux Fault] has opened its contact
  • A condition elsewhere in the application is deliberately blocking the drive
  • An open circuit in the wiring to that input

First checks, in this order

  1. Read P157 [DI Aux Fault] to find which terminal is assigned
  2. Check the state of that input and the device wired to it
  3. Close the interlock or repair the wiring, then clear the fault

Fault 3: Power Loss

Warning: act before it becomes a stop

What it means: The DC bus voltage stayed below the power loss level for longer than the power loss time, which means the incoming supply dipped or dropped out. Out of the box the 753/755 shows this as a type 1 alarm, but it can be set to fault.[1][4][5]

Also on: 753 and 755: configurable with P449 [Power Loss Actn], default 1 Alarm (type 1), options Ignore, Flt Minor, FltCoastStop; auto restart and auto clear allowed. 755T: Power Loss is 10001 (11001); 755T code 3 is Emerg OVRD Actv. PowerFlex 525: F003 Power Loss means single phase operation with excessive load, a different trigger.

Likely causes

  • Incoming AC supply dropped out or sagged
  • Input voltage outside the drive specification
  • Power loss level or time set too tight for the site supply

First checks, in this order

  1. Check P11 [DC Bus Volts] and measure the incoming line on all three phases
  2. Check P449 [Power Loss Actn] and the [Pwr Loss n Level] and [Pwr Loss n Time] settings
  3. Check input fuses, breaker and any input contactor

Fault 4: UnderVoltage

Hits OEE: Availability

What it means: The DC bus voltage in P11 [DC Bus Volts] fell below the level set in P461 [UnderVltg Level]. With the default action the drive faults and coasts to a stop.[1][2][4][5]

Also on: 753 and 755: configurable with P460 [UnderVltg Action], default 3 FltCoastStop; auto restart and auto clear allowed. 755T: UnderVoltage is 10106 (11106); 755T code 4 is Energy Pause Cfg. PowerFlex 525: F004 UnderVoltage has the same meaning.

Likely causes

  • Low incoming line voltage or a short supply interruption
  • P461 [UnderVltg Level] set too close to the normal bus voltage

First checks, in this order

  1. Read P11 [DC Bus Volts] and measure the AC line at the drive input
  2. Check input fuses and power connections
  3. Review P460 [UnderVltg Action] and P461 [UnderVltg Level]

Fault 5: OverVoltage

Hits OEE: Availability

What it means: The DC bus voltage went above the drive maximum. It nearly always comes from energy flowing back from the motor, or from a high or unstable supply.[1][2][4][5]

Also on: 753 and 755: resettable fault, coast stop, not configurable; auto restart and auto clear allowed. 755T: OverVoltage is 10107 (11107), 13066 on the line side converter. PowerFlex 525: F005 OverVoltage has the same meaning.

Likely causes

  • Regenerated energy from an overhauling or high inertia load while slowing down
  • Decel too fast with bus regulation off and no dynamic brake
  • High or unstable AC input line voltage

First checks, in this order

  1. Check P11 [DC Bus Volts] and the AC line for high voltage or transients
  2. Lengthen the decel time and review P372/P373 [Bus Reg Mode n]
  3. If the load regenerates often, fit and set up a dynamic brake resistor (P382 to P385)

Fault 7: Motor Overload

Hits OEE: Availability

What it means: The drive's electronic motor overload, which follows the curve of a class 10 overload relay, has tripped. The motor drew more than its rated current for too long.[1][2][4][5]

Also on: 753 and 755: configurable with P410 [Motor OL Actn], default 3 FltCoastStop; auto restart and auto clear allowed. 755T: Motor Overload is 10003 (11003), alarm 10002; 755T code 7 is an emergency override event. PowerFlex 525: F007 Motor Overload has the same meaning.

Likely causes

  • Mechanical load above the motor rating
  • P26 [Motor NP Amps] or P413 [Mtr OL Factor] set below the motor nameplate
  • Long running at low speed with P414 [Mtr OL Hertz] derating the overload

First checks, in this order

  1. Compare P7 [Output Current] with P26 [Motor NP Amps]
  2. Check P26, P413 and P414 against the motor nameplate and service factor
  3. Look for binding or extra load on the driven machine

Fault 8: Heatsink OvrTemp

Hits OEE: Availability

What it means: The heatsink temperature passed 100 percent of the drive's thermal rating and the drive stopped to protect the power module.[1][2][4][5]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: Heatsink OvrTemp is 10094 (11094), 13046 on the converter; 755T code 8 is an emergency override event. PowerFlex 525: F008 Heatsink OvrTmp has the same meaning.

Likely causes

  • Blocked airflow, dirty heatsink or filters, or a cooling fan not running
  • Cabinet ambient above the drive rating
  • Sustained load at or above the drive rating

First checks, in this order

  1. Read P943 [Drive Temp Pct] and P944 [Drive Temp C]
  2. Check the fans, heatsink fins and cabinet filters
  3. Check cabinet temperature and load against the drive rating and derating

Fault 9: Trnsistr OvrTemp

Hits OEE: Availability

What it means: The output transistors (IGBTs) went past their maximum operating temperature as modeled by the drive. It can trip at high current and low output frequency even when the heatsink reading looks fine.[1][2][5]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: numbered differently, see 750-RD100. PowerFlex 525: F009 is CC OvrTmp, the control module temperature, a different sensor.

Likely causes

  • High output current at low output frequency
  • PWM frequency set high for the load, or above 2 kHz on a chiller plate
  • The same cooling problems that cause fault 8

First checks, in this order

  1. Read P941 [IGBT Temp Pct] and P942 [IGBT Temp C]
  2. Check P38 [PWM Frequency]; on a chiller plate Rockwell requires 2 kHz
  3. Check P420 [Drive OL Mode] so the drive can lower PWM or current limit before it trips

Fault 10: DynBrake OvrTemp

Warning: act before it becomes a stop

What it means: The drive's model of the dynamic brake resistor says it is above its maximum temperature. As a type 1 alarm, a running drive keeps going but a stopped drive cannot start until it clears.[1]

Also on: 753 and 755: type 1 alarm. 755T: numbered differently, see 750-RD100. PowerFlex 525: 750-Series only number.

Likely causes

  • Brake resistor too small for how hard or how often the machine brakes
  • P382 [DB Resistor Type] to P385 [DB ExtPulseWatts] not matching the fitted resistor

First checks, in this order

  1. Check P382 to P385 against the resistor nameplate
  2. Compare the braking duty with the resistor rating
  3. Check the resistor's own over temperature circuit, which Rockwell requires on external resistor packages

Fault 12: HW OverCurrent

Hits OEE: Availability

What it means: Output current went past the hardware current limit, a very fast trip that protects the transistors. It usually points to a short, a ground or a sudden heavy load.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: HW OverCurrent is 10093 (11093), 13053 on the converter. PowerFlex 525: F012 HW OverCurrent has the same meaning but is a type 2 (non auto resettable) fault there.

Likely causes

  • Grounded or shorted motor or motor cable
  • Excess load or a sudden jam
  • Programming that drives current too high

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then check motor leads and terminals
  2. Insulation resistance (megger) test the motor and the cable
  3. Check the load and the programming for causes of excess current

Fault 13: Ground Fault

Hits OEE: Availability

What it means: Current is leaking from the drive output to earth at more than 25 percent of the drive rating. The drive shuts off its output at once.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed; event 14 Ground Warning can give an earlier alarm. 755T: Ground Flt shows as 12026 (inverter) or 14026 (converter), not 13. PowerFlex 525: F013 Ground Fault has the same meaning; on the 525 auto restart tries it only once.

Likely causes

  • Grounded condition in the motor cable or at the drive output terminals
  • Motor winding insulation breaking down to the frame
  • On a 755T, a failed power module if it still faults with no motor connected

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then disconnect the motor leads at the drive
  2. Insulation resistance test the motor and the cable separately
  3. If both test good, run the drive with no motor; if it still faults, suspect the drive

Fault 14: Ground Warning

Warning: act before it becomes a stop

What it means: Ground current is above the level in P467 [Ground Warn Lvl] but below a hard ground fault. It is an early sign that insulation is getting worse.[1][4]

Also on: 753 and 755: configurable with P466 [Ground Warn Actn], default 0 Ignore, options Alarm, Flt Minor or fault stops. 755T: M Ground Warning is 10080 (11080). PowerFlex 525: 750-Series only number.

Likely causes

  • Motor or cable insulation starting to break down
  • P467 [Ground Warn Lvl] set low for the installation

First checks, in this order

  1. Check P466 [Ground Warn Actn] and P467 [Ground Warn Lvl]
  2. Plan an insulation resistance test of motor and cable at the next stop
  3. If it is set as a fault, it will not clear until ground current drops below P467

Fault 15: Load Loss

Hits OEE: Availability

What it means: Torque current stayed below P442 [Load Loss Level] for longer than P443 [Load Loss Time]. It is used to catch a motor running with its load disconnected.[1][4][5]

Also on: 753 and 755: configurable with P441 [Load Loss Action], default 0 Ignore, can be Alarm or a fault. 755T: Load Loss is 10004 (11004); on the 755T code 15 means AuRsts Exhausted. PowerFlex 525: F015 Load Loss has the same meaning (525 only, not 523).

Likely causes

  • Coupling, belt or shaft link between motor and load broken or slipping
  • Level or time set too tight for normal light load running

First checks, in this order

  1. Check the mechanical link from motor to machine
  2. Compare normal running torque with P442 and P443
  3. Check P441 [Load Loss Action]

Fault 17: Input Phase Loss

Hits OEE: Availability

What it means: Ripple on the DC bus went above the preset level, which the drive reads as a lost or badly unbalanced input phase. Running like this stresses the bus capacitors.[1][2][4][5]

Also on: 753 and 755: configurable with P462 [InPhase LossActn], default 3 FltCoastStop. 755T: Input Phase Loss is 10005 (11005); 755T code 17 is CPU OverTemp Flt. PowerFlex 525: single phase input shows as F003 Power Loss instead.

Likely causes

  • One supply phase failing while the other two stay live
  • Unbalanced input line impedance
  • Cyclic loads or speed loop tuning making the bus ripple swing

First checks, in this order

  1. Measure all three input phases and check the input fuses
  2. Check input impedance balance
  3. Only with a healthy supply, raise P463 [InPhase Loss Lvl] or tune the bus or speed regulator, as Rockwell lists

Fault 18: Motor PTC Trip

Hits OEE: Availability

What it means: The PTC thermistor in the motor reports over temperature. The motor itself is too hot, whatever the drive current shows.[1][4]

Also on: 753: event 18 from the main board PTC input, configured by P250 [PTC Cfg], default Ignore. 755: the PTC sits on an I/O option module and shows with the port number in front (xx002, for example 4002). 755T: PTC Over Temp is option code nn011. PowerFlex 525: 750-Series only number.

Likely causes

  • Motor overheating from load, low speed running or poor ventilation
  • Open or broken PTC sensor wiring

First checks, in this order

  1. Check motor temperature and its cooling
  2. Check the PTC wiring and P250 [PTC Cfg] on a 753, or the I/O module PTC setting on a 755

Fault 19: Task Overrun

Warning: act before it becomes a stop

What it means: The main control board processor is at or above 90 percent of its capacity. Too many options or functions are loading it.[1]

Also on: 753 and 755: type 1 alarm. 755T: numbered differently. PowerFlex 525: 750-Series only number.

Likely causes

  • Many option modules plus DeviceLogix and EtherNet/IP loading the processor
  • A configuration beyond the system resource allocation table

First checks, in this order

  1. Compare the installed options with the resource allocation table in 750-PM001
  2. Remove or disable unused option modules or DeviceLogix programs

Fault 20: TorqPrv Spd Band

Hits OEE: Availability

What it means: With TorqProve active, commanded speed and measured motor speed differed by more than P1105 [Speed Dev Band] for longer than P1106 [SpdBand Intgrtr]. On a hoist it means the load is not following the drive.[1][4]

Also on: 755 only (TorqProve): resettable fault, coast stop. 755T: TorqPrv Spd Band is 10007 (11007). PowerFlex 525: 750-Series only number.

Likely causes

  • Motor speed not tracking the command, such as a slipping load or brake
  • Speed band or integrator time set too tight
  • Speed loop bandwidth too low for the application

First checks, in this order

  1. Compare P2 [Commanded SpdRef] with P3 [Mtr Vel Fdbk]
  2. Check the brake and the encoder
  3. Review P1105 and P1106

Fault 21: Output PhaseLoss

Hits OEE: Availability

What it means: Current in one or more motor phases was missing or below P445 [Out PhaseLossLvl] for 1 second (5 ms with TorqProve). Something between drive and motor is open.[1][4][5]

Also on: 753 and 755: configurable with P444 [OutPhaseLossActn], default 0 Ignore. 755T: Output PhaseLoss is 10008 (11008); 755T code 21 is the Clr Fault Queue event. PowerFlex 525: F021 Output Ph Loss has the same meaning.

Likely causes

  • Open output contactor or loose motor lead
  • Motor much smaller than the drive, so phase current sits under the threshold
  • With TorqProve: brake slipping or no brake fitted

First checks, in this order

  1. Check the output contactor, disconnect and motor terminations
  2. If the motor is small for the drive, lower P445
  3. With TorqProve faulting on start, increase P44 [Flux Up Time]

Fault 24: Decel Inhibit

Hits OEE: Availability

What it means: The drive is not following the commanded decel because it is holding back to keep the DC bus voltage down. The load is pushing energy back faster than the drive can take it.[1][4]

Also on: 753 and 755: configurable with P409 [Dec Inhibit Actn], default 3 FltCoastStop. 755T: Decel Inhibit is 10009 (11009); 755T code 24 is Board OT Alarm. PowerFlex 525: 750-Series only number.

Likely causes

  • Bus regulation halting decel because of regenerated energy
  • High inertia load with a short decel time
  • Unstable AC input line voltage

First checks, in this order

  1. Lengthen the decel time
  2. Review P372/P373 [Bus Reg Mode n]; Rockwell suggests disabling bus regulation and adding a dynamic brake where needed
  3. For high inertia loads in V/Hz or SVC, set P621 [Slip RPM at FLA] to 0
  4. Check P409 [Dec Inhibit Actn]

Fault 25: OverSpeed Limit

Hits OEE: Availability

What it means: Motor speed went past the maximum speed plus P524 [Overspeed Limit]. The load or the speed loop drove the motor faster than allowed.[1][4]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: OverSpeed Limit is 10010 (11010); 755T code 25 is Board UT Fault. PowerFlex 525: 750-Series only number.

Likely causes

  • Overhauling load pushing the motor past the command
  • Max speed or overspeed limit set too close to running speed
  • Wrong velocity feedback in flux vector modes, where P131 [Active Vel Fdbk] sets the speed

First checks, in this order

  1. Check P520 [Max Fwd Speed], P521 [Max Rev Speed] and P524
  2. Check P131 [Active Vel Fdbk] in flux vector modes or P1 [Output Frequency] in other modes
  3. For closed loop, check encoder setup and mounting

Fault 26: Brake Slipped

Warning: act before it becomes a stop

What it means: After the brake was set, the encoder saw more movement than P1110 [Brk Slip Count]. The mechanical brake is not holding the load.[1][4]

Also on: 755 TorqProve only: type 1 alarm while the brake slip routine controls the drive, type 2 alarm once it has finished and the drive is stopped. 755T: 10011 BrakeSlippedActv and 10012 BrakeSlippedStop; 755T code 26 is Board UT Alarm. PowerFlex 525: 750-Series only number.

Likely causes

  • Worn or misadjusted mechanical brake
  • Brake slip count set too low

First checks, in this order

  1. Make the load safe and inspect the brake
  2. Check P1110 [Brk Slip Count]
  3. Cycle power to reset, as Rockwell states

Fault 29: Analog In Loss

Hits OEE: Availability

What it means: An analog input set to watch for signal loss has lost its signal. The speed or process reference from that input can no longer be trusted.[1][4][5]

Also on: 753: event 29 from the main board analog input, configurable with P263, default Ignore. I/O option modules report it with the port number in front (xx001, for example 4001). 755T: Analog In0 Loss is option code nn001; 755T code 29 is Port 1 Adapter. PowerFlex 525: F029 Analog In Loss has the same meaning.

Likely causes

  • Broken or loose analog signal wiring
  • Transmitter or PLC analog output failed or unpowered

First checks, in this order

  1. Measure the signal at the analog input terminals
  2. Check the loss action: P263 [Anlg In0 LssActn] on the 753 main board, or the I/O module setting
  3. Check the source device

Fault 33: AuRsts Exhausted

Hits OEE: Availability

What it means: Auto restart tried to reset a fault and restart the drive the number of times in P348 [Auto Rstrt Tries] and failed each time. The original fault is still there.[1][2][4][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: AuRsts Exhausted is code 15; 755T code 33 is Port 5 Adapter. PowerFlex 525: F033 Auto Rstrt Tries has the same meaning.

Likely causes

  • A repeating fault that auto restart cannot clear
  • The cause of the first fault was never fixed

First checks, in this order

  1. Open the fault queue to find the fault that kept returning
  2. Fix that cause, then clear manually
  3. Review P347 [Auto Retry Fault], P348 and P349 [Auto Rstrt Delay]

Fault 34: AutClrFltExhaust

Hits OEE: Availability

What it means: The auto clear function, which clears certain faults while the drive is stopped, used up its tries in P338 [AutoClrFlt Tries]. It is only reported when bit 1 of P347 [Auto Retry Fault] is set.[1][4]

Also on: 753 and 755: resettable fault, coast stop. 755T: code 34 is Port 6 Adapter. PowerFlex 525: 750-Series only number.

Likely causes

  • A fault that keeps coming back while the drive is stopped
  • The underlying cause is still present

First checks, in this order

  1. Check the fault queue for the repeating fault
  2. Fix it, then clear manually
  3. Review P338, P339 [AutoClrFlt Delay] and P347

Fault 35: IPM OverCurrent

Hits OEE: Availability

What it means: Current passed the trip level in P1640 [IPM Max Cur], used with interior permanent magnet motor control. Rockwell says to set P1640 to 0 only when the drive runs in V/Hz or SVC mode.[1][4]

Also on: 755 (P1640 is a 755 parameter): resettable fault, coast stop; auto restart and auto clear allowed. 755T: code 35 is Port 1 DPI Loss. PowerFlex 525: 750-Series only number.

Likely causes

  • Motor current above the P1640 trip level
  • P1640 not set to suit the motor or the control mode

First checks, in this order

  1. Check P35 [Motor Ctrl Mode] and P1640
  2. Check the load and the motor data
  3. Check motor and cable for shorts as for fault 12

Fault 36: SW OverCurrent

Hits OEE: Availability

What it means: Output current passed the drive's 1 ms rating, which sits between the 3 second rating and the hardware overcurrent trip, typically 200 to 250 percent of continuous rating. It is a software trip just under fault 12.[1][2][4][5]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: SW OverCurrent is 10092 (11092), 13092 on the converter; 755T code 36 is Port 2 DPI Loss. PowerFlex 525: F063 is named SW OverCurrent but on the 525 it means a shear pin level was exceeded.

Likely causes

  • Sudden heavy load or jam
  • Starting into a spinning load without flying start
  • Short or contactor switching between drive and motor

First checks, in this order

  1. Check for jams and shock loads
  2. If starting into a rotating load, check flying start settings
  3. Check motor and cable insulation and any output contactor

Fault 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 the U (T1) phase.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, not in the auto restart list; events 44 to 46 (Phase NegToGrnd) are handled the same way. 755T: Phase U to Grnd is 10016 (11016); 755T code 38 is Port 4 DPI Loss. PowerFlex 525: F038 Phase U to Gnd has the same meaning.

Likely causes

  • Damaged insulation on the U lead between drive and motor
  • Motor winding grounded on that phase
  • A drive problem, if the fault stays on U after the leads are swapped

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then megger the motor and cable
  2. Rotate the U/T1, V/T2 and W/T3 output connections
  3. If the fault follows the wire, fix the field wiring; if it stays on the same phase, suspect the drive

Fault 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 the V (T2) phase.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, not in the auto restart list; events 44 to 46 (Phase NegToGrnd) are handled the same way. 755T: Phase V to Grnd is 10017 (11017); 755T code 39 is Port 5 DPI Loss. PowerFlex 525: F039 Phase V to Gnd has the same meaning.

Likely causes

  • Damaged insulation on the V lead between drive and motor
  • Motor winding grounded on that phase
  • A drive problem, if the fault stays on V after the leads are swapped

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then megger the motor and cable
  2. Rotate the U/T1, V/T2 and W/T3 output connections
  3. If the fault follows the wire, fix the field wiring; if it stays on the same phase, suspect the drive

Fault 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 the W (T3) phase.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, not in the auto restart list; events 44 to 46 (Phase NegToGrnd) are handled the same way. 755T: Phase W to Grnd is 10018 (11018); 755T code 40 is Port 6 DPI Loss. PowerFlex 525: F040 Phase W to Gnd has the same meaning.

Likely causes

  • Damaged insulation on the W lead between drive and motor
  • Motor winding grounded on that phase
  • A drive problem, if the fault stays on W after the leads are swapped

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then megger the motor and cable
  2. Rotate the U/T1, V/T2 and W/T3 output connections
  3. If the fault follows the wire, fix the field wiring; if it stays on the same phase, suspect the drive

Fault 41: Phase UV Short

Hits OEE: Availability

What it means: Too much current was measured between output terminals U and V, which points to a short between those two phases.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, not in the auto restart list. 755T: Phase UV Short is 10019 (11019). PowerFlex 525: F041 Phase UV Short has the same meaning.

Likely causes

  • Short between the U and V conductors in the motor cable or terminal box
  • Shorted motor winding
  • A drive problem, if the fault does not follow the wires

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then check the cable and motor terminal box
  2. Insulation test phase to phase on the motor and cable
  3. Rotate the U/T1, V/T2 and W/T3 connections; if it follows the wire it is field wiring, if not suspect the drive

Fault 42: Phase VW Short

Hits OEE: Availability

What it means: Too much current was measured between output terminals V and W, which points to a short between those two phases.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, not in the auto restart list. 755T: Phase VW Short is 10020 (11020). PowerFlex 525: F042 is Phase UW Short, a different pair; the 525 calls the V and W pair F043.

Likely causes

  • Short between the V and W conductors in the motor cable or terminal box
  • Shorted motor winding
  • A drive problem, if the fault does not follow the wires

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then check the cable and motor terminal box
  2. Insulation test phase to phase on the motor and cable
  3. Rotate the U/T1, V/T2 and W/T3 connections; if it follows the wire it is field wiring, if not suspect the drive

Fault 43: Phase WU Short

Hits OEE: Availability

What it means: Too much current was measured between output terminals W and U, which points to a short between those two phases.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop, not in the auto restart list. 755T: Phase WU Short is 10021 (11021); 755T code 43 is PwrDn NVS Blank. PowerFlex 525: F043 is Phase VW Short; the 525 calls the W and U pair F042 Phase UW Short.

Likely causes

  • Short between the W and U conductors in the motor cable or terminal box
  • Shorted motor winding
  • A drive problem, if the fault does not follow the wires

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then check the cable and motor terminal box
  2. Insulation test phase to phase on the motor and cable
  3. Rotate the U/T1, V/T2 and W/T3 connections; if it follows the wire it is field wiring, if not suspect the drive

Fault 48: System Defaulted

Hits OEE: Availability

What it means: The drive was told to write default values to its parameters. The setup is now factory values until you reload it.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: System Defaulted is code 18 (755T code 2 is Sys Default Fail). PowerFlex 525: F048 Params Defaulted has the same meaning.

Likely causes

  • A reset to defaults from the HIM, software or network
  • Parameters defaulted as part of fixing another fault

First checks, in this order

  1. Clear the fault
  2. Reload the saved parameter file or reprogram the drive before running

Fault 55: Ctrl Bd Overtemp

Hits OEE: Availability

What it means: The temperature sensor on the main control board read too hot. The control electronics, not the power section, are overheating.[1][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: numbered differently. PowerFlex 525: the nearest is F009 CC OvrTmp (control module temperature).

Likely causes

  • Cabinet ambient above the product temperature rating
  • Poor airflow around the control pod

First checks, in this order

  1. Check cabinet temperature and ventilation
  2. Compare with the product temperature requirement in the installation instructions

Fault 59: Invalid Code

Hits OEE: Availability

What it means: The firmware detected an internal error. On the 753/755 this number is unrelated to safety inputs.[1][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: numbered differently. PowerFlex 525: F059 means Safety Open (safety inputs S1 and S2 not enabled); on the 753/755 safety problems show as faults 210 to 213 or as the Safety bit in P933 [Start Inhibits].

Likely causes

  • Internal control error reported by firmware
  • Rockwell's table gives no field cause beyond internal error

First checks, in this order

  1. Clear the fault and cycle power
  2. If it returns, note the fault queue and firmware revision and contact Rockwell technical support

Fault 61: Shear Pin 1

Hits OEE: Availability

What it means: Output current went above P436 [Shear Pin1 Level] for longer than P437 [Shear Pin 1 Time]. It works as an electronic shear pin to catch a jam or stall.[1][2][4][5]

Also on: 753 and 755: configurable with P435 [Shear Pin 1 Actn], default 0 Ignore; auto restart and auto clear allowed. 755T: Shear Pin 1 is 10025 (11025); 755T code 61 is the Invalid RTC Time event. PowerFlex 525: shear pin trips show as F063 SW OverCurrent.

Likely causes

  • Jam, stall or binding in the driven machine
  • Level or time set below the normal peak load

First checks, in this order

  1. Inspect the machine for a jam
  2. Compare P7 [Output Current] at the trip with P436
  3. Review P435 [Shear Pin 1 Actn] and P437

Fault 62: Shear Pin 2

Hits OEE: Availability

What it means: Output current went above P439 [Shear Pin2 Level] for longer than P440 [Shear Pin 2 Time]. The second shear pin is often set as a separate stall or jam level.[1][2][4][5]

Also on: 753 and 755: configurable with P438 [Shear Pin 2 Actn], default 0 Ignore; auto restart and auto clear allowed. 755T: Shear Pin 2 is 10026 (11026); 755T code 62 is the RTC HW Failed event. PowerFlex 525: shear pin trips show as F063 SW OverCurrent.

Likely causes

  • Jam, stall or binding in the driven machine
  • Level or time set below the normal peak load

First checks, in this order

  1. Inspect the machine for a jam
  2. Compare P7 [Output Current] at the trip with P439
  3. Review P438 [Shear Pin 2 Actn] and P440

Fault 64: Drive OverLoad

Hits OEE: Availability

What it means: The drive's own thermal overload count, P940 [Drive OL Count], reached 100 percent and the drive stopped to protect its power module. Between 50 and 100 percent the same number shows as a type 1 alarm.[1][2][4][5]

Also on: 753 and 755: type 1 alarm above 50 percent, resettable fault at 100 percent, coast stop; auto restart and auto clear allowed; Rockwell says the detection itself cannot be disabled. 755T: Drive OverLoad is 10027 (alarm) and 10028 (fault); 755T code 64 is a power cycle counter event. PowerFlex 525: F064 Drive Overload has the same meaning.

Likely causes

  • Load above the drive rating for too long
  • Wrong derating for temperature and altitude, or blocked airflow
  • Fold back of PWM and current limit turned off in P420 [Drive OL Mode]

First checks, in this order

  1. Reduce the mechanical load or lengthen accel time
  2. Check P940 [Drive OL Count] and P420 [Drive OL Mode]
  3. Check the drive is sized and derated for the duty, and check cabinet filters

Fault 71: Port 1 Adapter

Hits OEE: Availability

What it means: The DPI communication option in port 1 reported a fault of its own. Events 72 to 76 mean the same for ports 2 to 6.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: Port 1 to 6 Adapter are codes 29 to 34; 755T code 71 is Bipolar Conflict. PowerFlex 525: F071 is DSI Net Loss, loss of control over Modbus or DSI.

Likely causes

  • A fault inside the communication adapter or on its network
  • Adapter setup problem

First checks, in this order

  1. Read the event queue of the device in that port
  2. Check the adapter's network cable and settings

Fault 79: Excessive Load

Hits OEE: Availability

What it means: During autotune the motor did not reach speed in the allotted time.[1][4]

Also on: 753 and 755: resettable fault, coast stop. 755T: Excessive Load is 10031 (11031). PowerFlex 525: 750-Series only number.

Likely causes

  • Too much load on the motor during a rotating tune
  • Motor still coupled to the machine when the test needs it free

First checks, in this order

  1. Uncouple the motor or reduce the load and run the tune again
  2. For an induction motor, run a static tune instead
  3. With an encoder, do the direction test first

Fault 80: AutoTune Aborted

Hits OEE: Availability

What it means: Autotune was cancelled by hand or stopped because another fault occurred.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: AutoTune Aborted is 10032 (11032). PowerFlex 525: F080 Autotune Failure has a similar meaning.

Likely causes

  • A stop command during the tune
  • Another fault during the tune

First checks, in this order

  1. Check the fault queue for a second fault
  2. Make sure no stop is sent during the test, then run P70 [Autotune] again

Fault 81: Port 1 DPI Loss

Hits OEE: Availability

What it means: The device on DPI port 1, normally the HIM in the drive cradle, stopped communicating. With the default setting the drive faults and coasts.[1][3][4][5]

Also on: 753 and 755: resettable fault by default; P865 options Fault, Stop, Zero Data, Hold Last, Send Flt Cfg (the last four give a type 2 alarm instead); auto restart and auto clear allowed. 755T: Port 1 DPI Loss is code 35. PowerFlex 525: F081 DSI Comm Loss is loss of the Modbus or DSI master, a different port.

Likely causes

  • HIM removed while it was a control source, without using the REMOVE HIM key
  • Loose or damaged HIM or cradle connection
  • Poor drive grounding

First checks, in this order

  1. Check the HIM is seated and its connections are good
  2. Check drive grounding
  3. Review P865 [DPI Pt1 Flt Actn] and P324 [Logic Mask]

Fault 82: Port 2 DPI Loss

Hits OEE: Availability

What it means: The device on DPI port 2 stopped communicating. A remote or handheld HIM cable connects to DPI Port 2.[1][3][4][5]

Also on: 753 and 755: resettable fault by default, action set by P866; auto restart and auto clear allowed; 83 to 86 cover ports 3 to 6. 755T: Port 2 DPI Loss is code 36. PowerFlex 525: F082 is Opt Comm Loss, loss of the network option card.

Likely causes

  • HIM cable unplugged from DPI Port 2 while it was a control source
  • Damaged cable or connector

First checks, in this order

  1. Check the cable and connector at DPI Port 2
  2. Use the REMOVE HIM soft key before unplugging a HIM
  3. Review P866 [DPI Pt2 Flt Actn] and P324 [Logic Mask]

Fault 91: PriVelFdbk Loss

Hits OEE: Availability

What it means: The device chosen as primary velocity feedback reported a loss, or the feedback module stopped talking to the main control board.[1][4][5]

Also on: 753 and 755: configurable, the loss action lives in the feedback option module parameters. 755T: Pri VelFdbk Loss is option code nn034. PowerFlex 525: F091 Encoder Loss is the 525 counterpart.

Likely causes

  • Encoder or feedback cable fault
  • Feedback option module problem
  • Communication loss between the feedback module and the main control board

First checks, in this order

  1. Check P125 [Pri Vel Fdbk Sel] and the module it points to
  2. Check encoder wiring and the feedback module's own fault codes
  3. If using auto tach switch, check P128 [Alt Vel Fdbk Sel]

Fault 100: Parameter Chksum

Hits OEE: Availability

What it means: Parameter data read from memory failed its checksum, so the drive set the data to default values.[1][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: numbered differently. PowerFlex 525: F100 Parameter Chksum has the same name; the 525 fix is a factory reset with P053 [Reset To Defalts].

Likely causes

  • Stored parameter data corrupted
  • Data set to defaults by the drive as a result

First checks, in this order

  1. Clear the fault
  2. Reload the saved parameter file or reprogram
  3. If it keeps returning, contact Rockwell technical support

Fault 106: Incompat MCB-PB

Hits OEE: Availability

What it means: The main control board did not recognize the power structure it is fitted to.[1][4][5]

Also on: 753 and 755: non-resettable fault, coast stop. 755T: code 106 is Port 6 Cfg. PowerFlex 525: F106 Incompat C-P is a similar control and power module mismatch.

Likely causes

  • Main control board firmware older than the power structure needs
  • Control board and power structure that do not match

First checks, in this order

  1. Flash the drive with a newer application revision, as Rockwell directs
  2. Check the control board and power structure catalog numbers

Fault 107: Replaced MCB-PB

Hits OEE: Availability

What it means: The main control board was moved to a different power structure, so the drive set its data to defaults.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: code 107 is Port 7 Cfg. PowerFlex 525: F107 Replaced C-P means the control module could not recognize the power module.

Likely causes

  • Control board swapped between drives
  • Control board replaced on this power structure

First checks, in this order

  1. Clear the fault
  2. Reload the correct parameter file for this drive

Fault 111: PwrBd Invalid ID

Hits OEE: Availability

What it means: The main control board read an invalid power structure ID from the power board.[1][5]

Also on: 753 and 755: non-resettable fault, coast stop. 755T: numbered differently. PowerFlex 525: F111 is Safety Hardware, a safety input fault; the 753/755 safety jumper faults are 210, 212 and 213.

Likely causes

  • Loose or damaged ribbon cable between the main control board and the power interface board
  • Failed power interface board

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then reseat the ribbon cable
  2. If it persists, replace the power interface board

Fault 138: Precharge Open

Hits OEE: Availability

What it means: The internal precharge was told to open while the drive was running. The latch clears by itself once PWM is off.[1][4]

Also on: 753 and 755: resettable fault, coast stop; auto restart and auto clear allowed. 755T: PrechargeOpenFlt is 10042 (alarm 10041). PowerFlex 525: 750-Series only number.

Likely causes

  • Low DC bus voltage that sent the drive back into precharge
  • Precharge control settings in P321 [Prchrg Control], P189 [DI Precharge] or P190 [DI Prchrg Seal]

First checks, in this order

  1. Check P11 [DC Bus Volts] and the incoming supply
  2. Check P321 and any precharge digital inputs on common bus systems

Fault 152: No Stop Source

Hits OEE: Availability

What it means: The last device able to send a stop command has been removed, so the drive faults.[1][3][4]

Also on: 753 and 755: resettable fault, coast stop. 755T: No Stop Source is code 171 (and 10047). PowerFlex 525: 750-Series only number.

Likely causes

  • HIM unplugged while it was the only stop source
  • Stop digital input or network link removed

First checks, in this order

  1. Connect and set up a stop source
  2. Use the REMOVE HIM key before unplugging a HIM

Fault 157: DigIn Cfg B

Warning: act before it becomes a stop

What it means: Two digital input functions that cannot exist together were assigned, such as Run and Start. The drive will not start until this is fixed.[1][4]

Also on: 753 and 755: type 2 alarm, not configurable; 158 DigIn Cfg C is the related alarm for two functions on one input. 755T: DigIn Cfg B is code 73. PowerFlex 525: 750-Series only number.

Likely causes

  • 2 wire (Run) and 3 wire (Start) functions mixed
  • Start set up without a Stop
  • Mutually exclusive choices such as Jog and Jog Forward

First checks, in this order

  1. Review the digital input assignments against the conflict table in 750-PM001
  2. Remove one of the conflicting functions
  3. Confirm P961 [Type 2 Alarms] bit 9 clears

Fault 168: HeatSinkUnderTmp

Hits OEE: Availability

What it means: The heatsink sensor reads below -18.7 C (-1.66 F), or its circuit is open.[1][4]

Also on: 753 and 755: resettable fault. 755T: HeatSinkUnderTmp is 10109 (11109). PowerFlex 525: 750-Series only number.

Likely causes

  • Drive installed in a very cold area
  • Open heatsink temperature sensor circuit

First checks, in this order

  1. Read P943 [Drive Temp Pct] and P944 [Drive Temp C]
  2. If the room is not that cold, suspect the sensor circuit and contact Rockwell support

Fault 169: PWM Freq Reduced

Warning: act before it becomes a stop

What it means: The drive lowered its PWM frequency below P38 [PWM Frequency] because IGBT junction temperature is high. It warns that the drive is near its thermal limit.[1][4]

Also on: 753 and 755: type 1 alarm. 755T: PWM Freq Reduced is 10050 (11050). PowerFlex 525: 750-Series only number.

Likely causes

  • Load needing too much current
  • Wrong derating for temperature and altitude
  • Blocked airflow

First checks, in this order

  1. Check load and drive sizing
  2. Check cooling and filters
  3. See P420 [Drive OL Mode]

Fault 170: CurLimit Reduced

Warning: act before it becomes a stop

What it means: Current limit was lowered from [Current Limit n] because of high IGBT junction temperature or because P940 [Drive OL Count] reached 95 percent.[1][4]

Also on: 753 and 755: type 1 alarm. 755T: CurLimit Reduced is 10051 (11051). PowerFlex 525: 750-Series only number.

Likely causes

  • Load needing too much current
  • Wrong derating for temperature and altitude
  • Blocked airflow

First checks, in this order

  1. Check load and drive sizing
  2. Check cooling and filters
  3. See P420 [Drive OL Mode]

Fault 210: HW Enbl Jmpr Out

Hits OEE: Availability

What it means: A safety option module is installed but the ENABLE jumper on the main control board is removed. It applies to Frames 1 to 7.[1][4][5]

Also on: 753 and 755 Frames 1 to 7: resettable fault, coast stop. 755T: HW Enbl Jmpr Out is code 86; 755T code 210 is Fiber Offline 7. PowerFlex 525: 750-Series only number; the 525 reports safety input trouble as F059 or F111.

Likely causes

  • ENABLE jumper removed or not refitted after service
  • Safety module added without refitting the jumper

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then install the ENABLE jumper per 750-IN001
  2. Clear the fault

Fault 211: Safety Brd Fault

Hits OEE: Availability

What it means: A safety option module (Safe Torque Off 20-750-S, Safe Speed Monitor 20-750-S1 or ATEX 20-750-ATEX) reported a fault.[1][4][5]

Also on: 753 and 755: resettable fault, coast stop. 755T: Safety Brd Fault is code 87 and is non-resettable there; 755T code 211 is Fiber Offline 8. PowerFlex 525: F111 Safety Hardware is the closest 525 fault.

Likely causes

  • Safe Torque Off module supply dropping below 11 V DC (below 17 V DC it shows Not Enable)
  • ENABLE jumper missing
  • ATEX module: thermal sensor wiring shorted, hardware damage, or EMC noise from poor grounding or shielding

First checks, in this order

  1. Verify the ENABLE jumper is installed
  2. Check the safety module supply and its own status (P67 [Fault Status] on the Safe Speed Monitor)
  3. Reset or power cycle; see 750-UM002, 750-RM001 or 750-UM003 for that module

Fault 212: Safety Jmpr Out

Hits OEE: Availability

What it means: The SAFETY jumper is not fitted and no safety option module is installed, so the drive has neither.[1][4]

Also on: 753 and 755: resettable fault, coast stop. 755T: Safety Jmpr Out is code 88; 755T code 212 is Fiber Offline 9. PowerFlex 525: 750-Series only number.

Likely causes

  • SAFETY jumper removed
  • Safety module removed without refitting the jumper

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then install the SAFETY jumper on the main control board
  2. If a safety module should be present, check it is installed

Fault 213: Safety Jumper In

Hits OEE: Availability

What it means: The SAFETY jumper is fitted while a safety option module is installed. The jumper and the module must not be used together.[1][4]

Also on: 753 and 755: resettable fault, coast stop. 755T: Safety Jumper In is code 89; 755T code 213 is Fiber Offline 10. PowerFlex 525: 750-Series only number.

Likely causes

  • Safety module added and the jumper left in place
  • Jumper refitted by mistake during service

First checks, in this order

  1. Lock out all power and confirm zero DC bus voltage before touching wiring, then remove the SAFETY jumper
  2. Clear the fault and prove the safety circuit works

Fault 224: Port 4 Comm Loss

Hits OEE: Availability

What it means: The option module in port 4 stopped talking to the main control board. Events 225 to 228 mean the same for ports 5 to 8.[1][4]

Also on: 753 and 755: configurable with P965 [Option Loss Actn], default 0 Fault; auto restart and auto clear allowed. 755T: code 224 is Fiber Offline 21, a different event. PowerFlex 525: 750-Series only number.

Likely causes

  • Module not seated in its port or mounting screws not tight
  • Module failed or removed
  • Network connection problem for that module

First checks, in this order

  1. Check the module is present, seated and screwed down
  2. Check its network connections
  3. Check P965 [Option Loss Actn] and P966 [Option Loss Dly]

Fault 315: Excess Psn Err

Hits OEE: Availability

What it means: Position error went past its absolute maximum value. The motor fell too far behind or ahead of the commanded position.[1][4]

Also on: 753 and 755: configurable, set from the Logix controller. 755T: Excess Psn Err is 10076 (11076); 755T code 315 is Inv ACP Fbr Cfg. PowerFlex 525: 750-Series only number.

Likely causes

  • Motor unable to follow the commanded move because of load, binding or limits
  • Position error limit set from the Logix controller too tight for the move

First checks, in this order

  1. Check the position error limit configured in the Logix controller
  2. Check for binding and for torque or current limits holding the motor back
  3. Check the position feedback device

Fault 322: N-1 Operation

Warning: act before it becomes a stop

What it means: A paralleled PowerFlex 755 (Frame 9 and larger) is running with fewer inverters than its original setup. It runs at reduced current and power limits until the missing assembly is back.[1][4]

Also on: 755 Frame 9 and larger with parallel inverters: type 1 alarm that stays on while reconfigured; 360 N-1 See Manual is the related fault. 755T: code 322 is Op Mode Mismth, a different event. PowerFlex 525: 750-Series only number.

Likely causes

  • An inverter assembly taken out of service with the N-1 procedure
  • Reconfiguration after an inverter assembly failed

First checks, in this order

  1. Check the new rating in Port 10 P21 [Effctv I Rating]
  2. Accept with Port 10 P20 [Recfg Acknowledg] once you agree
  3. Plan repair of the failed assembly; see N-1 and Re-Rate Functions in 750-PM001

Log it, or the same alarm comes back

A drive fault stops the motor and with it the conveyor, pump or fan the line depends on, so in OEE terms it is a breakdown. Log the fault number, the drive and the minutes lost.

  • Reason code: the number plus the drive, for example PF755 fault 13, extruder 2, so a ground fault that returns after every washdown stands out.
  • 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

How do I reset a fault on a PowerFlex 753 or 755?

Fix the cause first, because the drive faults again if the condition is still there. Then press the CLR soft key or the Stop key on the HIM, pulse the digital input assigned in P156 [DI Clear Fault], set the Clear Fault bit in the logic command word from the PLC, or cycle power. Non-resettable faults need the cause repaired and clear on the next power up.

What is the difference between a fault, a type 1 alarm and a type 2 alarm?

A fault stops the drive and has to be cleared. A type 1 alarm is a configurable warning: a running drive keeps running, but a stopped drive cannot start until it clears. A type 2 alarm is a configuration conflict that cannot be switched off, and the drive will not start until the parameters are corrected.

Why does my HIM show a four or five digit code like 4001 or 14037?

Codes from option modules carry the port number in front of the event number. Ports 1 to 9 use the format PEEE, so 4001 is event 1 (Analog In Loss) on the module in port 4, and ports 10 to 14 use PPEEE, so 14037 is event 37 on port 14. Look the event up in that module's table in 750-PM001, not in the main drive table.

Where can I see the fault history on a PowerFlex 755?

On the HIM select Port 00, open the DIAGNOSTIC folder and choose Faults or Alarms; entry 01 is the newest, the fault queue holds 32 entries, and pressing Enter shows the time stamp. P951 [Last Fault Code] shows the first fault since the last reset, which is often the root of a chain of faults. Clearing a fault does not empty the queue; that is a separate choice in the HIM menu.

Are PowerFlex 525 F codes and 755T codes the same as the 753/755 numbers?

Partly for the 525 and mostly not for the 755T. Many 525 F codes share the number and meaning (F4, F5, F7, F12, F13, F38 to F40), but some differ, such as F59 Safety Open against 59 Invalid Code, and the F42/F43 phase pairs. The TotalFORCE 755T uses its own list in 750-RD100, where ground fault is 12026 or 14026 and overvoltage is 10107, so check which drive you have before looking up a number.

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 750-Series AC Drives Programming Manual, publication 750-PM001Q-EN-P (November 2024), firmware 1.015 to 20.003
  2. PowerFlex 750-Series AC Drives Reference Manual, publication 750-RM002C-EN-P (February 2016)
  3. PowerFlex 20-HIM-A6 and 20-HIM-C6S HIM (Human Interface Module) User Manual, publication 20HIM-UM001E-EN-P (May 2017)
  4. PowerFlex Drives with TotalFORCE Control Conditions Reference Data, publication 750-RD100 (spreadsheet)
  5. PowerFlex 520-Series Adjustable Frequency AC Drive User Manual, publication 520-UM001O-EN-E (September 2025)

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.

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Related: Allen-Bradley Kinetix fault codes · MicroLogix fault codes · VFD drive troubleshooting · electric motor

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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