Allen Bradley PowerFlex 400 Drive Fault Codes List

Complete guide to Allen Bradley PowerFlex 400 fault codes. Troubleshoot HVAC-specific issues, F63 SW OverCurrent, Damper Control trips, and Pump Staging errors.

PowerFlex 400 Fault Codes Reference Table

Fault Codes Cause & Solutions
F2
Auxiliary
Input		 Cause : Auxiliary input interlock is open.

Solution:

- Check remote wiring.
- Verify communications programming for intentional fault.
F3
Power Loss		 Cause: Excessive DC Bus voltage ripple.

Solution:

- Monitor the incoming AC line for low voltage or line power interruption.
- Check input fuses.
- Reduce load.
F4
UnderVoltage		 Cause: DC bus voltage fell below the min value.

Solution: Monitor the incoming AC line for low voltage or line power interruption.
F5
OverVoltage		 Cause: DC bus voltage exceeded max value.

Solution:

- Monitor the AC line for high line voltage or transient conditions.
- Bus overvoltage can also be caused by motor regeneration.
- Extend the decel time or install dynamic brake option.
F6
Motor
Stalled 		 Cause: Drive is unable to accelerate or decelerate motor.

Solution:

- Increase P039...A147 [Accel Time x] or reduce load so drive output current does not exceed the current set by parameter A179 [Current Limit 1].
- Check for overhauling load.
F7
Motor
Overload		 Cause: Internal electronic overload trip.

Solution:

- An excessive motor load exists. Reduce load so drive output current does not exceed the current set by parameter P033 [Motor OL Current].
- Verify A170 [Boost Select] setting.
F8
Heatsink
OvrTmp		 Cause: Heatsink/Power Module temperature exceeds a predefined value.

Solution:

- Check for blocked or dirty heatsink fins. Verify that ambient temperature has not exceeded the rated ambient temperature.
- Check fan.
F12
HW
OverCurrent		 Cause: The drive output current has exceeded the hardware current limit.

Solution:

- Check programming.
- Check for excess load, improper A170 [Boost Select] setting, DC brake volts set too high or other causes of excess current.
F13
Ground
Fault		 Cause: A current path to earth ground has been detected at one or more of the drive output terminals.

Solution:

- Check the motor and external wiring to the drive output terminals for a grounded condition.
F15
Load Loss		 Cause: Output current has dropped below the level set in A184 [Load Loss Level].

Solution:

- Check for load loss (i.e., a broken belt).
F17
Input Phase
Loss		 Cause: Excessive DC bus ripple voltage detected. See d329 [DC Bus Ripple V].

Solution:

- Check incoming power for a missing phase or blown fuse. If drive is used intentionally with single phase input, apply output derating to 35% actual drive rating.
F29
Analog Input
Loss		 Cause: An analog input is configured to fault on signal loss. A signal loss has occurred.
- Configure with T072 [Anlalog In Loss].

Solution:

- Check parameters.
- Check for broken/loose connections at inputs.
F32
Fan Fdbck
Loss		 Cause: A loss of cooling fan feedback has been detected. (Frames E and F only)

Solution:

- Make sure cooling fans are clear of debris and spinning freely. Replace fan if necessary.
F33
Auto Rstrt
Tries		 Cause: Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A163 [Auto Rstrt Tries].

Solution:

- Correct the cause of the fault and manually clear.
F38
Phase U
to Gnd		 Cause: A phase to ground fault has been detected between the drive and motor in this phase.

Solution:

- Check the wiring between the drive and motor.
- Check motor for grounded phase.
- Replace drive if fault cannot be cleared.
F39
Phase V
to Gnd		 Cause: A phase to ground fault has been detected between the drive and motor in this phase.

Solution:

- Check the wiring between the drive and motor.
- Check motor for grounded phase.
- Replace drive if fault cannot be cleared.
F40
Phase W
to Gnd		 Cause: A phase to ground fault has been detected between the drive and motor in this phase.

Solution:

- Check the wiring between the drive and motor.
- Check motor for grounded phase.
- Replace drive if fault cannot be cleared.
F41
Phase
UV Short		 Cause: Excessive current has been detected between these two output terminals.

Solution:

- Check the motor and drive output terminal wiring for a shorted condition.
- Replace drive if fault cannot be cleared.
F42
Phase
UW Short		 Cause: Excessive current has been detected between these two output terminals.

Solution:

- Check the motor and drive output terminal wiring for a shorted condition.
- Replace drive if fault cannot be cleared.
F43
Phase
VW Short		 Cause: Excessive current has been detected between these two output terminals.

Solution:

- Check the motor and drive output terminal wiring for a shorted condition.
- Replace drive if fault cannot be cleared.
F48
Params
Defaulted 		 Cause: The drive was commanded to write default values to EEPROM.

Solution:

- Clear the fault or cycle power to the drive.
- Program the drive parameters as needed.
F63
SW
OverCurrent		 Cause: Programmed A183 [SW Current Trip] has been exceeded.

Solution:

- Check load requirements and A183 [SW Current Trip] setting.
F64
Drive
Overload		 Cause: Drive rating of 110% for 1 minute or 150% for 3 seconds has been exceeded.

Solution: Reduce load or extend Accel Time.
F70
Power Unit		 Cause: Failure has been detected in the drive power section.

Solution:

- Check that max ambient temperature has not been exceeded.
- Cycle power.
- Replace drive if fault cannot be cleared.
F71
Net Loss 		 Cause: The communication network has faulted.

Solution:

- Cycle power.
- Check communications cabling.
- Check network adapter setting.
- Check external network status.
F81
Comm Loss		 Cause: RS485 (DSI) port stopped communicating.

Solution:

- Check RS485 wiring connection.
- Check if a communications adapter or HIM was disconnected.
- Increase C106 [Comm Loss Time] to an appropriate time for application.
- Change C105 [Comm Loss Action] to a value other than “0” (fault), if appropriate for the application.
F94
Function
Loss		 Cause: P036 [Start Source] is set to setting 6.
- The input to terminal 01 has been opened.

Solution:

- Close input to terminal 01 and re- start the drive.
F100
Parameter
Chksum		 Cause: The checksum read from the board does not match the checksum calculated.

Solution: Set P041 [Reset To Defalts] to option 1 “Reset Defaults”.
F122
I/O Board
Fail		 Cause: Failure has been detected in the drive control and I/O section.

Solution:

- Cycle power.
- Replace drive if fault cannot be cleared.

 

How to Read PowerFlex 400 Faults

Diagnosing the PowerFlex 400 differs slightly from general industrial drives because of its building automation features. Here is how to access diagnostic data:

  • Integral Keypad: The 4-digit LED display flashes “F” followed by the code number.
    • Note: If the display reads “SLEEP,” the drive is not faulted. It is in “Sleep Mode” waiting for the PID demand (e.g., pressure or temperature) to rise above the wake level.
  • Fault History (d007 – d009):
    • d007: Most Recent Fault
    • d008: Fault 2
    • d009: Fault 3
  • Building Automation Systems (BAS): The PowerFlex 400 has built-in RS485 for Metasys N2, P1-FLN, and Modbus. In 2026, most facilities monitor these drives remotely. Check your BAS front-end to see if a “Loss of Flow” or “High Pressure” alarm preceded the drive fault.

Frequently Asked Questions (FAQ)

Q: How do I reset a PowerFlex 400 fault?

A: You can reset the drive via:

  • The red Stop/Reset button on the keypad.
  • Cycling main power.
  • A Digital Input configured for “Clear Fault” (often wired to a remote reset button in the MCC).
  • A command sent over the network (Modbus/Metasys/EtherNet/IP).

Q: What is Fault F63 “SW OverCurrent”?

A: This is very common in Fan applications. It indicates the current exceeded the hardware limit (usually >200%).

  • On Start: The fan might be windmilling (spinning backward due to draft). Enable “Flying Start” (Parameter A160).
  • During Run: Check for a blocked duct or closed valve that suddenly opened, causing a rush of load.

Q: Why won’t the drive start (No Fault displayed)?

A: The PowerFlex 400 often uses a “Damper Input” or “Run Permissive.”

  • Check if the Damper Control is active. The drive will not start until it receives confirmation (via digital input) that the air damper is fully open.
  • Check if the drive is in “Sleep” mode (PID feedback is satisfied).

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