AFE1 Emergency Stop (OFF2) Fault in ABB ACS580 Drive

AFE1 Emergency Stop (OFF2) in the ABB ACS580 Drive indicates that the drive has received an Emergency Stop (OFF2) command. The ACS580 immediately stops the motor using the configured OFF2 stop mode to protect personnel and equipment. This fault is typically generated when an emergency stop push button, safety relay, PLC, or other configured emergency stop source becomes active.

This fault generally indicates that the Emergency Stop circuit has been activated, either intentionally or unintentionally, rather than a fault in the drive or motor.

Possible Causes

• Emergency stop push button has been pressed.
• Emergency stop safety circuit is active.
• Parameter 21.05 – Emergency Stop Source is configured incorrectly.
• External safety relay has opened.
• PLC has issued an Emergency Stop command.
• Broken wire in the emergency stop circuit.
• Loose control wiring.
• Faulty emergency stop push button.
• Faulty safety relay.
• Incorrect digital input assignment.
• External interlock activated.
• Incorrect commissioning settings.
• Control circuit failure.
• Faulty digital input.
• Internal control board input failure.

Solutions

• Ensure it is safe to continue operation before resetting the Emergency Stop.
• Return the emergency stop push button to its normal position.
• Reset the emergency stop circuit.
• Restart the drive.
• If the emergency stop was not intentional, verify Parameter 21.05 – Emergency Stop Source.
• Check the assigned digital input.
• Inspect the emergency stop wiring for loose or damaged connections.
• Verify the operation of the emergency stop push button.
• Check the safety relay for proper operation.
• Verify PLC emergency stop signals if used.
• Confirm the external safety circuit has reset correctly.
• Repair or replace faulty control components if necessary.
• Contact ABB technical support if the fault persists after inspection.

Additional Information

The ABB ACS580 supports an Emergency Stop (OFF2) function that immediately stops the drive when an emergency stop command is received.

The emergency stop source is selected using:

• Parameter 21.05 – Emergency Stop Source

The OFF2 stop mode is typically connected to:

• Emergency stop push buttons.
• Safety relays.
• Safety PLCs.
• External protection systems.
• Machine safety circuits.

When the selected emergency stop signal becomes active, the drive:

• Stops the motor using the configured OFF2 stop method.
• Blocks further operation.
• Displays AFE1 Emergency Stop (OFF2) until the emergency condition is cleared.

ABB recommends verifying that it is safe to restart the equipment before resetting the emergency stop circuit.

If the fault occurs without the emergency stop being intentionally activated, ABB recommends checking the signal source configured by Parameter 21.05 – Emergency Stop Source.

Unlike electrical protection faults, AFE1 is a safety-related control fault indicating that the drive has intentionally stopped due to an Emergency Stop command.

Common Symptoms

• Drive displays AFE1 Emergency Stop (OFF2).
• Motor stops immediately.
• Drive will not restart.
• Emergency stop push button is pressed.
• Safety relay is active.
• Start command is ignored.
• Fault appears immediately after activating the emergency stop.
• PLC indicates Emergency Stop active.
• Fault clears after resetting the emergency stop circuit.
• No motor or inverter hardware fault is present.

Recommended Troubleshooting Sequence

1. Verify that it is safe to restart the machine.
2. Return the emergency stop push button to its normal position.
3. Reset the emergency stop circuit.
4. Restart the drive.
5. Verify Parameter 21.05 – Emergency Stop Source.
6. Check the assigned digital input.
7. Inspect emergency stop wiring.
8. Verify the emergency stop push button operation.
9. Check the safety relay.
10. Verify PLC or safety controller signals.
11. Inspect control wiring for damage.
12. Repair faulty components if required.
13. Restart the drive.
14. Verify normal operation.
15. Contact ABB technical support if the fault persists.

Emergency Stop (OFF2) Check Table

Check Point	Action
Machine safety	Ensure it is safe to restart
Emergency stop push button	Return to normal position
Emergency stop circuit	Reset the circuit
Drive restart	Restart the drive
Parameter 21.05	Verify Emergency Stop Source
Digital input	Check assigned input status
Emergency stop wiring	Inspect for loose or damaged connections
Safety relay	Verify proper operation
PLC/Safety controller	Confirm Emergency Stop signal status
Control wiring	Inspect for faults
ABB technical support	Contact if the fault remains after inspection

Preventive Maintenance Tips

• Test emergency stop push buttons regularly.
• Inspect emergency stop wiring during scheduled maintenance.
• Verify Parameter 21.05 – Emergency Stop Source after commissioning or parameter changes.
• Periodically test safety relays and safety PLC functions.
• Keep emergency stop devices clean and free from mechanical damage.
• Tighten control terminals during preventive maintenance.
• Document emergency stop circuit modifications.
• Verify proper operation after replacing control components.
• Train operators on correct Emergency Stop reset procedures.
• Record recurring AFE1 faults to assist long-term diagnostics.

Proper verification of the Emergency Stop circuit, correct configuration of Parameter 21.05 – Emergency Stop Source, routine inspection of the emergency stop push button, safety relay, control wiring, and digital inputs, along with ensuring that the machine is safe before restarting, will help prevent recurring AFE1 Emergency Stop (OFF2) faults in ABB ACS580 drives, ensuring safe operation, reliable machine protection, and dependable long-term performance of the drive system.