An F111 fault code indicates a safety hardware fault on your PowerFlex 525 Allen-Bradley drive. This means the drive detected an issue with the safety input circuit that prevents unintended motor starts and protects personnel from operational hazards.

Here's a breakdown of the F111 fault and how to troubleshoot it:

Understanding the Safety Circuit:

The PowerFlex 525 drive has dedicated safety input terminals (S1 and S2) that can be connected to external safety devices like emergency stop buttons, safety limit switches, or light curtains. When these safety devices are activated, they interrupt the safety circuit, preventing the drive from starting or stopping the motor.

Causes of F111 Fault:

• Open Safety Circuit: The most common cause of the F111 fault is an open circuit on the safety input terminals (S1 and S2). This could be due to:

• Disconnected or damaged safety devices: Ensure all safety devices are properly connected and functioning correctly.
• Loose wiring: Check for any loose or broken wires on the safety circuit terminals.
• Faulty safety relay (if used): If you're using an external safety relay in the circuit, it might be malfunctioning.

• Drive Misconfiguration: In some cases, the F111 fault might occur due to incorrect configuration of the safety input settings in the drive parameters.

Troubleshooting Steps:

1. Verify Safety Devices: Make sure all safety devices connected to the drive are functioning properly and not accidentally triggered.
2. Inspect Safety Circuit Wiring: Visually inspect the wiring between the safety devices and the drive's S1 and S2 terminals for any signs of damage or loose connections.
3. Check Drive Configuration: Consult the PowerFlex 525 user manual for instructions on accessing and verifying the safety input settings in the drive parameters.
4. Reset Fault (Optional): If you've addressed the cause (e.g., tightened loose wires, replaced a faulty safety device), you can try resetting the F111 fault on the drive. Refer to the user manual for specific instructions on fault reset procedures for your model.