PowerFlex 755T/755TS fault codes (TotalFORCE): how codes are numbered, common faults and safe reset

On the PowerFlex 755T, 755TL, 755TM, 755TR and 755TS (TotalFORCE, firmware 10 and later), fault codes are no longer in the user manuals. Rockwell keeps every fault, alarm and event in the 750-RD102 workbook, PowerFlex Drives with TotalFORCE Control Conditions Reference Data, which goes with programming manual 750-PM101 (firmware 10.xxx…14.xxx). This article uses edition 750-RD102D-EN-P, whose Summary of Changes is dated 30 May 2025.

The code number tells you where the fault is

Rockwell calls faults, alarms and events conditions. Each sheet in 750-RD102 covers one port inside the drive, and the leading digits of a code are that port number:

• On the "Port 10, 11" sheet each condition has two codes: 10001 and 11001 are both "Power Loss". Per migration guide 750-RM102, port 10 holds the primary motor control profile and port 11 is used when a secondary motor control mode is configured.
• Port 13 and Port 14 rows describe the line side converter: Ln power modules, AC precharge, LCL filter. Some Port 14 rows name 755TR and 755TL drives and 755TM bus supplies (for example 14135), and 750-RM102 Table 3 lists 755TS ports only up to 12. So a 13xxx or 14xxx code points to the supply side, not the motor side.
• On the Options sheet, "nn" is the port number of the slot the module is installed in, 04 to 08 (RD102 Port 0, codes 267–270: the port number is the first two digits of the code; 750-RM102 Table 3). The same nn code means different things on different modules: nn005 is "Relay0 Life" on an I/O module but "STO Fault" on a 20-750-S3, so always read the Option column.
• The Numeric List sheet lists every code in number order. Set Excel to search the whole workbook, not just the open sheet, as QA77928 and the Introduction sheet advise.

Condition types

The Condition Type column tells you how the drive reacts:

• Resettable Fault: the drive trips; a reset clears it once the cause is gone.
• Non-Resettable Fault: a reset alone is usually not enough. The Action column for this group mostly says power down or cycle power and check configuration, jumpers or fiber-optic connections, then replace the named board or module if the fault persists. Only a few call for a parameter redownload (301, 302) or firmware work (307, 309, 324, 10111 / 11111, 13067).
• Configurable: the response is set by the parameter in the Configuration Parameter column, with the choices in Configurable Action. Example: 10003 "Motor Overload" uses 10:200 [Mtr OL Action] (Ignore, Alarm, Flt Minor, FltCoastStop, Flt RampStop, Flt CL Stop); converter-side 13003 "Phase Loss Det" uses 13:176 [LSCPhLossDetActn] (Ignore, Type 2 Alarm, Ride Thru, Major Fault).
• Alarm 1 / Alarm 2 (type 1 / type 2 alarms): warnings. Alarm 1 includes many early threshold warnings such as 10002 "Mtr Ovrld Alarm"; Alarm 2 includes many configuration conflicts such as 104 "Port 4 Cfg".
• Minor Fault (on Port 9, e.g. 9014 "TP Encls Config") and Event, a log entry rather than a fault (e.g. 77 "Drive Reset", 351 "Net Link 1 Down").

The Fault Action column also states whether the fault opens the main circuit breaker and whether it can reset automatically. TDL's advice: do not set a configurable fault to Ignore just to get through a shift; that switches the protection off.

Codes commonly seen in plants

Every code and display text below matches 750-RD102 exactly; the explanations are TDL's own. Search the code in the workbook for full detail.

Step by step

1. Read the queue on the HIM or in Connected Components Workbench: fault queue, plus alarm and event queues if needed. The code prefix shows which port raised it.
2. Record before clearing: photo, time, whether the drive was running or decelerating, and the parameters the Fault column names, such as 0:3 [DC Bus Volts], 10:363 [Heatsink Temp] or 10:357 [Drive OL Count]. Clearing the queue is itself logged as 21 "Clr Fault Queue", but the earlier faults are gone.
3. Look it up across the whole workbook: Fault, Action and Fault Action columns.
4. Fix the cause, then reset. A fault that returns straight after a reset means the cause is still there.
5. Reset safely. A reset can restart the motor immediately if a run command from the PLC, an input or the network is still present. Clear the hazard zone and follow site lockout and permit-to-work rules. With auto restart enabled (0:60 [Auto Retry Fault], 0:61 [Auto Rstrt Tries], 0:62 [Auto Rstrt Delay]), a fault may have reset itself several times; when tries run out the drive shows 15 "AuRsts Exhausted" and the original fault is in the queue.
6. Non-resettable faults: follow the Action column, usually power down or cycle power and check configuration, jumpers or fiber-optic connections; the named board or module is replaced only if the fault persists. Before opening the cabinet, isolate, wait the capacitor discharge time on the drive label and confirm with a meter.

When it is hardware

For some codes the Action column points to replacing parts per service manual 750-TG100 (755T) or 750-TG101 (755TS): 12017 "Gate Drive Flt" (Mn power module), 12051 "Bus PosFuseBlown" (find the cause, replace both DC link fuses), 12137 "Pwr Struc Fault" (replace the drive).

TDL does not repair circuit boards. Replacement modules, boards or drives go through Rockwell Automation or a Rockwell-authorised service provider; TDL can help narrow down the fault, back up and restore the configuration, and recheck the system afterwards.

Before calling for support

Record the catalog number (bulletin 20G or 20J) and firmware; code, text, type, port and time; photos of the fault and event queues; whether it repeats or lines up with a supply event or start; and a parameter backup.

On a 755TS in Integrated Motion mode, conditions are reported as CIP Motion codes; the CIP Motion Mapping sheet maps the two numbering schemes (e.g. 1 "Auxiliary Input" is condition code 523, subcode 35). Planning a move from 755 to 755TS: see PowerFlex 755 to 755TS migration.

Need an engineer on site: request support.