ABB ACS580 Warning AFE1 Emergency Stop (OFF2)

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Getting the AFE1 warning on your ABB ACS580 drive? Learn what the OFF2 Emergency Stop means, how to reset the safety circuit, and the step-by-step process to restart your VFD.

ABB ACS580 Warning AFE1 Emergency Stop (OFF2)

 

If you are operating an ABB ACS580 general-purpose drive and the motor suddenly coasts to a stop while the control panel flashes Warning AFE1, your system has entered a safety-related shutdown.

The good news is that AFE1 is an informative warning, not a sign of internal hardware damage. It simply means the drive is obeying an Emergency Stop (OFF2) command. In this guide, we will break down what this means and the exact steps you need to take to get back to production.

What is an OFF2 Emergency Stop?

In the ABB ecosystem, "OFF2" refers to a Coast-to-Stop. When this signal is triggered, the drive immediately stops modulating (disconnects power from the motor). Unlike a ramped stop (OFF1 or OFF3), the motor is left to spin down naturally due to its own friction and inertia.

Safety Note: An Emergency Stop occurs because the system detected a potential hazard. Never reset an E-stop until you have physically inspected the machine to ensure no personnel are at risk and no mechanical damage has occurred.

Common Causes of AFE1

  • Physical E-Stop Button: A hardwired emergency stop button on the cabinet or the machine has been pressed.
  • PLC Signal: The master controller has sent a "0" bit in the Control Word via Fieldbus (PROFINET, Modbus, etc.).
  • Safety Relay Trip: An upstream safety module or light curtain has opened the safety loop.
  • Wiring Issue: A loose wire at a digital input assigned to the emergency stop function.

Step-by-Step Recovery Guide

Step 1: Verify Site Safety

Walk around the machine. Is there a reason someone pressed the stop button? Ensure the area is clear of tools, debris, or personnel. Only proceed once you are certain it is safe for the motor to rotate again.

Step 2: Reset the Physical Hardware

Locate the physical E-Stop button that was activated. Most buttons are "latching" and will stay depressed until you manually release them.

  • Twist or pull the E-stop button back to its normal (ready) position.
  • If your machine has a secondary safety reset button (usually blue or white on the cabinet door), press it to re-energize the safety relay loop.

Step 3: Clear and Restart the Drive

Once the physical signal is restored, the ACS580 usually needs a "handshake" before it will run again.

  1. Check the Control Panel. The AFE1 warning should disappear once the safety circuit is closed.
  2. If the warning persists, press the [Reset] button on the drive keypad.
  3. Apply a fresh Start command: For safety, the drive will NOT restart automatically. You must toggle your start switch (Stop then Start) or send a new start bit from your PLC.

Advanced Troubleshooting: Unintentional AFE1

If the AFE1 warning appears but no one pressed an E-stop, you need to check the Source of the command in the parameters:

  • Check Parameter 21.05: Navigate to Menu > Parameters > Group 21 and check Emergency stop source.
  • Verify if it is set to a digital input (e.g., DI6). Check the wiring at that specific terminal. If the screw is loose or the wire is broken, the drive will see 0V and trigger an AFE1 stop.

Summary Checklist

Action Result
1. Inspect Machine Ensures mechanical safety and personnel protection.
2. Reset Button Restores the physical 24V signal to the safety input.
3. Reset Drive Clears the AFE1 warning from the display history.
4. New Start Command Initiates the motor run sequence manually.

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