Allen-Bradley Fault Code Reference

Type 04 Code 16 is a Program Major fault indicating the controller encountered an unknown instruction during execution. This typically occurs when a program is incompletely downloaded, the firmware version does not support a particular instruction, or an Add-On Instruction (AOI) is missing. Resolve by re-downloading the program from Studio 5000, verifying firmware compatibility, and checking for missing AOIs.

To clear a major fault: (1) Connect with Studio 5000 or RSLogix 5000, (2) Go to Controller Properties > General, (3) Click "Clear Major Fault", (4) Address the root cause shown in the fault code before switching to Run mode. You can also clear faults programmatically using GSV/SSV instructions on the FaultLog object. For Type 01 faults (nonrecoverable), a power cycle or firmware reinstall via ControlFLASH may be required.

PowerFlex F012 is a hardware overcurrent fault indicating the drive output current instantly exceeded the protection threshold. Causes include output short circuits, motor insulation breakdown, or ground faults. Diagnose by: (1) Measuring motor cable insulation resistance with a megger, (2) Checking motor phase-to-phase and phase-to-ground resistance, (3) Disconnecting the motor cable and testing the drive standalone, (4) Inspecting the drive IGBT module for damage, (5) Verifying motor cable length is within the allowable range.

Kinetix S10 indicates the difference between commanded and actual position exceeded the configured tolerance. Common causes include mechanical jams or interference, insufficient servo tuning gains, aggressive acceleration/deceleration profiles, and encoder signal quality issues. Troubleshoot by manually checking the mechanism for binding, re-tuning axis parameters, moderating accel/decel rates, reviewing the Position Error Tolerance setting, and verifying encoder cable shielding.

For Type 07 I/O faults: (1) Check the physical module LEDs for error indication (red flashing), (2) Verify the module is properly seated in the backplane or base, (3) Confirm the module catalog number and series match the I/O tree configuration in Studio 5000, (4) Check if the module firmware version matches the project Electronic Keying settings, (5) For 24VDC field power loss (Code 10), measure voltage at the module field power terminals and verify the external power supply.

Type 03 Code 16 indicates an I/O connection was lost to a remote device on the EtherNet/IP network. Causes include network cable faults, switch port failures, device power loss, or IP address conflicts. Troubleshoot by checking device power and status LEDs, inspecting network cables and switch ports, running ping tests, reviewing RPI values and connection settings in the I/O tree, and scanning for duplicate IP addresses on the network.

PowerFlex F007 indicates the electronic thermal protection (I-squared-t) detected motor overheating from sustained overload. To resolve: (1) Verify the actual load current is within the motor rated current, (2) Ensure the Motor FLA (Full Load Amps) parameter correctly matches the motor nameplate, (3) Confirm Motor NP Amps matches the drive parameter settings, (4) Inspect motor cooling including fan and ventilation, (5) Reduce the mechanical load or consider upsizing the motor if it is undersized for the application.

Type 06 Code 01 is a ControlNet connection fault indicating a scheduled connection failure. Causes include ControlNet module hardware failure or coaxial/fiber cable faults. To resolve: (1) Inspect ControlNet cable connections (coax or fiber), (2) Run diagnostics in RSNetWorx for ControlNet, (3) Reschedule the network, (4) Check the ControlNet module NTWK LED status, (5) Update module firmware and reschedule the network. For duplicate node addresses (Code 02), scan the network and change the conflicting node address via the rotary switch.