Cause : Application load failure comes when the drive's application program fails to load correctly. The application program file may be corrupted or damaged, preventing it from loading successfully.

F545 Application load failure fault in ABB DCS800 drive indicates a problem with loading the drive's application software. This fault often means that the drive's application software has failed to start or load correctly, which can be due to corrupted files, incompatible firmware, or hardware issues with the control board.

Here’s how to troubleshoot and resolve this fault:

1. Power Cycle the Drive:

• Turn off the drive, wait for a few minutes, and then power it back on. This can sometimes reset temporary faults in loading the application software.

2. Check Application Software Version:

• Verify that the application software version loaded in the drive is compatible with your DCS800 firmware and hardware version. Incompatible versions may prevent the application from loading correctly.

3. Inspect Control Board and SDCS-COM Module:

• Check the control board and communication module for physical signs of damage, such as burn marks or corrosion, which may interfere with application loading.
• Ensure all connections to the control board and modules are secure, as poor connections can interrupt the application loading process.

4. Reset to Factory Settings:

• If possible, perform a factory reset on the drive to clear any configuration issues that could be affecting the application software load. Remember that this will reset all settings to default, so ensure you back up configurations beforehand if needed.

5. Replace SDCS-CON Board (If Necessary):

• If the fault persists after trying the above steps, the SDCS-CON board (control board) itself may be faulty. Replacing the control board may be necessary to restore normal function if it’s determined that the board is no longer reliable.