Allen-Bradley (Rockwell Automation) PowerFlex 525 fault F007: Motor Overload
Fault F007 on a PowerFlex 525 is Motor Overload: the drive’s internal electronic (I²t, Class 10) motor overload tripped because output current stayed above P033 [Motor OL Current] for too long. Rockwell’s actions are to reduce the load and verify A530 [Boost Select].
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When it happens
- Constant speed under sustained heavy load
- Repeated starts or long accelerations
- Low-speed running with V/Hz boost set high
- Not on an instant at start; the overload integrates over time
Likely causes and checks
1Motor genuinely overloaded
- Points to it
- Trips after minutes of running; output current is above the nameplate FLA; the motor is hot.
- Check
- Measure output current (b003) against the motor nameplate FLA and check the driven machine for binding, wear or process overload.
2P033 set lower than the motor nameplate
- Points to it
- Trips at normal load after commissioning or drive replacement.
- Check
- Compare P033 [Motor OL Current] with the nameplate FLA and the service-factor practice on site.
3Boost too high at low speed
- Points to it
- Trips while running slowly with light load; current at low speed is high.
- Check
- Check A530 [Boost Select] for the load type and the V/Hz settings.
4Low-speed derating
- Points to it
- Trips only at low speed on a self-cooled motor.
- Check
- Check A493 [Motor OL Select] (derating of the I²t function) against the motor’s cooling.
Telling it apart
- F007 is a time-based motor overload. F064 Drive Overload means the drive’s own overload rating was exceeded (Type 2). F012 HW OverCurrent is an instant hardware current limit.
- F006 Motor Stalled means the drive could not accelerate or decelerate because output current stayed at A484/A485 [Current Limit x] for too long.
- Rockwell notes the drive faults on F007 according to Class 10 motor overload protection (NEC article 430) based on P033.
Relevant parameters
| Parameter | Name | Why it matters |
|---|---|---|
| P033 | [Motor OL Current] | Motor nameplate overload current used for the I²t motor overload (0.1 A to 200% of drive rated current). |
| A493 | [Motor OL Select] | Derating factor for the I²t overload function (no, minimum or maximum derate). |
| A530 | [Boost Select] | Boost voltage for V/Hz modes; listed in the F007 action. |
Evidence to collect
- b007 and F641 [Fault 1 Current] at the trip
- P033 and the motor nameplate FLA and service factor
- A530 and A493 settings
- Run time before the trip and duty cycle
- Motor temperature and ventilation
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