Allen Bradley PowerFlex 4M Drive Fault Codes List

Complete guide to Allen Bradley PowerFlex 4M fault codes. Troubleshoot common F-codes (F4, F7), reset faults, and perform diagnostics using the integral keypad.

PowerFlex 4M 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 P109 and/or A402 [Accel Time x] or reduce load so drive output current does not exceed the current set by parameter A441 [Current Limit].
- 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 P103 [Motor OL Current].
- Verify A453 [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 A453 [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.
F33
Auto Rstrt
Tries		 Cause: Drive unsuccessfully attempted to reset a fault and resume running for the programmed number of A451 [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 A448 [SW Current Trip] has been exceeded.

Solution:

- Verify connections between motor and load.
- Check load requirements and A448 [SW Current Trip] setting.
F64
Drive
Overload		 Cause: Drive overload rating has been exceeded. Drive rating of 150% for 1 minute or 200% 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
DSI 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: RS-485 (DSI) port stopped communicating.

Solution:

1. If adapter was not intentionally disconnected, check wiring to the port. Replace wiring, port expander, adapters or complete drive as required.
2. Check connection.
3. An adapter was intentionally disconnected.
4. Turn off using C304 [Comm Loss Action].
F100
Parameter
Chksum		 Cause: The checksum read from the board does not match the checksum calculated.

Solution: Set P112 [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 4M Faults

Because the PowerFlex 4M is a compact component drive, it does not have the advanced logging features of the 750 or 520 series. However, you can still extract diagnostic data:

  • Integral Keypad: The most common method is reading the flashing red LED on the faceplate. It will flash “F” followed by the number (e.g., “F” … “4”).
  • Fault Buffer Parameters: The drive stores the last three faults in parameters d007 (Fault 1 – Most Recent), d008, and d009. accessing these via the keypad can tell you if a specific error is recurring.
  • PC Connection (DSI): To connect a PC in 2026, you need the 1203-USB converter connected to the RJ45 DSI port. Using Connected Components Workbench (CCW) software, you can view the “Status” bits to see if the drive is in a “Faulted” or “Alarm” state.

Frequently Asked Questions (FAQ)

Q: How do I reset a PowerFlex 4M fault?

A: There are three main ways to reset the drive:

  • Press the red Stop/Reset button on the integral keypad.
  • Cycle power (turn off the mains, wait for the display to go dark, then turn back on).
  • Set parameter A451 (Reset Fault) to “1” via the keypad.

Q: What causes the “F4 UnderVoltage” fault?

A: This is the most common fault on the PowerFlex 4M. It occurs when the DC bus voltage drops below a preset limit (typically 385V DC on a 480V drive). This usually happens due to:

  • Input power fluctuations or brownouts.
  • A blown fuse on the input side.
  • Power loss while the drive was running.

Q: Can I replace a PowerFlex 4M with a PowerFlex 523?

A: Yes. As the PowerFlex 4M ages, many users upgrade to the PowerFlex 523. However, the physical dimensions and wiring locations differ (Top-in/Bottom-out vs. Feed-through). You will need to adjust your mounting plate and wiring length during the retrofit.

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