Allen-Bradley troubleshooting answers

A Major Fault T07:C42 on a ControlLogix controller indicates a revision mismatch. This means the project in the controller's nonvolatile memory has a different firmware revision than the controller itself. This fault typ…

A Major Fault T07:C41 indicates a 'Load Type Mismatch' where the controller failed to load from nonvolatile memory because the project on the memory card was saved for a different controller type. This typically occurs a…

A Type 7 Code 40 fault on a ControlLogix controller indicates that storing the project to the nonvolatile memory card failed. This can occur during a project store operation or after a download with the store-to-nonvolat…

A Type 6 Code 1 fault, or Watchdog fault, indicates that a user task did not complete within its allotted watchdog time. This often occurs after program changes that introduce new logic or loops, causing the task to take…

A T04:C83 'Value Out of Range' major fault on a ControlLogix or CompactLogix controller indicates that a data value tested was outside its required limits. This specific fault type is associated with array subscripts use…

A Major Fault T04:C34, also known as a 'Negative Timer' fault, indicates that a timer instruction in the Logix 5000 controller program received a negative value for its preset (.PRE) or accumulated value (.ACC). This fau…

A ControlLogix or CompactLogix controller displays a Major Fault Type 4 Code 31 when a JSR instruction attempts to call a subroutine (SBR/RET) with fewer parameters than the subroutine expects. This fault occurs when the…

A ControlLogix or CompactLogix controller displaying a Major Fault T04:C20 indicates a program fault where an array subscript was too large for the array, or the .POS or .LEN value of a CONTROL structure was invalid. Thi…

A Major Fault T04:C16, or 'Unknown Instruction', indicates the controller encountered an instruction it doesn't recognize during program execution. This typically happens after a program download, especially if the proje…

A T03:C23 fault on a Logix 5000 controller indicates that a required I/O module connection was not established before the controller entered Run mode, within its configured time limit. This often occurs during the transi…

A T03:C16 major fault on a Logix 5000 controller indicates that a connection to a required I/O module has failed while the controller was in Run mode. This fault occurs only if the module is configured to cause a major f…

A Type 1 Code 1 (T01:C01) fault on a ControlLogix controller indicates that the controller powered up in Run or Remote Run mode after a power loss. This fault prevents the controller from automatically returning to norma…

The FLT S07 MTR OVERLOAD FL fault on an Allen-Bradley Kinetix 5700 servo drive indicates that the motor's thermal model has exceeded its factory-set thermal capacity limit. This fault often occurs after a demanding cycle…

The FLT S43 FDBK LOSS FL fault on a Kinetix 5700 servo drive indicates that the detected voltage levels of the A/B channel signals from the feedback device fell below the factory limit. This fault applies to all compatib…

The F081 DSI Comm Loss fault on a PowerFlex 525 drive indicates an interruption in communication between the drive and its Modbus or DSI master device. This fault is a Type 2 fault, and its response is determined by para…

Fault F033 on a PowerFlex 525 drive indicates that the drive attempted to reset a fault and resume operation for the configured number of attempts (A541 [Auto Rstrt Tries]) but failed. This is a Type 2 fault, meaning it …

A PowerFlex 525 F013 Ground Fault indicates the drive detected a current path to earth ground at one or more of its output terminals. This fault can occur at start, during operation (especially after washdown or cable mo…

The F012 HW OverCurrent fault on a PowerFlex 525 drive indicates the output current exceeded the hardware limit. This is a Type 2 fault, meaning it won't clear with an auto-restart. An instant trip at start, especially w…

The F007 Motor Overload fault on a PowerFlex 525 drive indicates that the drive's internal electronic motor overload protection (I²t, Class 10) has tripped. This occurs when the output current remains above the configure…

A PowerFlex 525 drive trips F005 (OverVoltage) when the DC bus voltage exceeds its maximum value. This often occurs during deceleration, especially with high-inertia or overhauling loads, or due to high line voltage. The…

Fault F004 on a PowerFlex 525 indicates that the DC bus voltage has dropped below the drive's minimum threshold. This is a Type 1 fault, meaning it can be cleared by an auto-restart. Common causes include supply dips, lo…