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Fault code lookup

PowerFlex 525 fault codes: what they mean and what to check first

What the common PowerFlex 525 fault codes mean, what usually causes them and what to check first – written in plain English from Rockwell Automation's own user manual, which stays the reference.

By Kunj Tapiawala, KIV Parts · Published · 8 min read

Quick answer

A PowerFlex 525 that faults stops the motor and flashes the fault number (F followed by a number, for example F004) with the red fault light. Read the code, find it in the table below, fix the cause, then clear it with the Stop key, a power cycle or A551 [Fault Clear]. Type 1 faults may reset by themselves if auto restart is set up; Type 2 faults need the cause fixed before they clear.

Jump to a code:

Safety first: lock out and tag out the drive and the machine before you open the drive or touch the wiring, and follow Rockwell Automation's procedure in the manual. The drive's DC bus capacitors stay charged after power is removed: the manual says to wait at least 3 minutes, then measure DC+ to DC–: a qualified person verifies zero voltage with a properly rated meter, checking the meter on a known source before and after – a dark display doesn't mean it's safe. Never bypass a safety circuit or switch off a fault to keep a machine running. Only qualified personnel should work on drives, and any measurement on energized equipment follows your site's live-work and arc-flash rules.

Reading and clearing a PowerFlex 525 fault

  1. Note the code. Press Esc to acknowledge the fault so you can use the keypad. b007 [Fault 1 Code] holds the latest fault, b008 and b009 the two before it, and F604 to F610 go back to the tenth.
  2. Look it up in the table below or in the manual, and fix the cause first – a fault whose cause is still there comes straight back.
  3. Clear it: press Stop (when P045 [Stop Mode] is set from 0 to 3), cycle power, set A551 [Fault Clear] to 1 “Reset Fault”, or use a digital input programmed as Clear Fault.
  4. Watch the restart. If the same code returns, go back through the checks before resetting again.

The PowerFlex 523 uses the same user manual and fault list; codes marked “PowerFlex 525 only” don't apply to it.

Common PowerFlex 525 fault codes

This list covers the codes technicians run into most often, not every code. The manual has the complete list and the full corrective actions.

CodeWhat it meansLikely causesFirst checks
F002Auxiliary InputType 1 The external trip input opened, or the network commanded a fault.
  • A device wired to a digital input set up as an external fault (overtemperature switch, interlock) opened
  • A loose wire on that input
  • The PLC or network program sent an intentional fault
  • Find what is wired to the input and why it opened
  • Check the remote wiring and terminals
  • Check the controller or network program for a deliberate fault
F003Power LossType 2 The drive saw single-phase input while carrying too much load.
  • A blown input fuse or a lost incoming phase
  • A loose line connection
  • Load too high for the supply
  • Have the three line voltages checked by a qualified electrician (live work), or log them with a power-quality recorder
  • Check the input fuses or breaker
  • Look for supply interruptions; reduce the load
F004UnderVoltageType 1 The DC bus voltage dropped below the drive's minimum.
  • Low incoming line voltage, dips or brownouts
  • A short interruption of the supply
  • A loose or failing line connection
  • Read b005 [DC Bus Voltage] first; checking the supply while running is live work for a qualified electrician, or use a power-quality recorder
  • Look for interruptions on the supply (other loads starting, a weak transformer)
  • Check line terminals and upstream connections
F005OverVoltageType 1 The DC bus voltage rose above the drive's maximum.
  • The motor regenerating energy while it slows a heavy or overhauling load
  • Deceleration time too short
  • High line voltage or transients on the supply
  • Lengthen the deceleration time
  • Read b005 [DC Bus Voltage] first; checking the incoming line is live work for a qualified electrician, or use a power-quality recorder
  • For loads that keep regenerating, look at the dynamic brake option in the manual
F006Motor StalledType 1 The drive could not accelerate or decelerate the motor; it was held at its current limit too long.
  • Acceleration time too short for the load
  • A jammed or binding machine
  • An overhauling load
  • Check that the machine turns freely (power locked out)
  • Lengthen the acceleration time or reduce the load
  • Review the current limit settings
F007Motor OverloadType 1 The drive's electronic motor overload protection tripped.
  • The motor drawing more than its set current for too long
  • Motor overload current set lower than the nameplate
  • Boost setting too high
  • Compare b003 [Output Current] with the motor nameplate
  • Check that P033 [Motor OL Current] matches the nameplate full-load amps
  • Check the mechanical load and the A530 [Boost Select] setting
F008Heatsink OvrTmpType 1 The heatsink / power module got too hot.
  • Blocked or dirty heatsink fins
  • A stopped or weak cooling fan
  • Enclosure or ambient temperature above the drive's rating
  • Clean the heatsink and check the airflow path
  • Check the fan
  • Measure the temperature around the drive against its rating
F012HW OverCurrentType 2 Output current went past the drive's hardware current limit.
  • A short or ground in the motor or motor cable
  • Too much load or a jam
  • Boost or DC brake voltage set too high
  • With power locked out, check the motor and cable for a shorted or grounded conductor
  • Check the load and the mechanics
  • Review the boost (A530) and DC brake settings
F013Ground FaultType 1 The drive found a current path to ground on one or more output terminals.
  • Damaged motor cable insulation
  • Moisture in the motor, the terminal box or the conduit
  • A motor winding with a fault to ground
  • With power locked out, inspect the motor and the output wiring for a grounded conductor
  • Look for water or contamination in the terminal box and conduit
  • Note: auto restart tries this fault only once
F015Load LossType 2PowerFlex 525 only Torque current stayed below the set load-loss level for longer than the set time.
  • A broken belt or coupling
  • A pump running dry or a lost load
  • Load-loss level or time set too tight
  • Check the connection between motor and load
  • Check A490 [Load Loss Level] and A491 [Load Loss Time]
F021Output Ph LossType 1 An output phase is missing (only when output phase loss detection is turned on).
  • An open conductor or loose terminal between drive and motor
  • An open contactor or disconnect in the motor circuit
  • An open motor winding
  • Check the motor wiring end to end
  • Check the motor
  • Detection is set by A557 [Out Phas Loss En]
F029Analog In LossType 1 An analog input set to fault on signal loss lost its signal.
  • A broken or loose analog signal wire
  • The 4-20 mA or voltage source failed or is unpowered
  • Check the input wiring and connections
  • Check the input's value on the drive's display first; measuring the signal at the terminals is live work for a qualified person
  • Check t094 [Anlg In V Loss] and t097 [Anlg In mA Loss]
F033Auto Rstrt TriesType 2 The drive used up its programmed auto-restart attempts without clearing the original fault.
  • The fault that started the restarts is still present
  • Read the fault history (b007 to b009, F604 to F610) for the original fault
  • Fix that cause, then clear the fault by hand
F038 / F039 / F040Phase U to GndType 2 A phase-to-ground fault was found between the drive and the motor on that phase (U, V or W).
  • Damaged insulation on that phase of the motor cable
  • A grounded motor winding
  • With power locked out, check the wiring between drive and motor
  • Check the motor for a grounded phase
  • The manual says to replace the drive if the fault cannot be cleared
F041 / F042 / F043Phase UV ShortType 2 Excessive current was found between two output terminals (U-V, U-W or V-W).
  • A phase-to-phase short in the motor cable or terminal box
  • A shorted motor winding
  • With power locked out, check the motor and output wiring for a short
  • The manual says to replace the drive if the fault cannot be cleared
F048Params DefaultedType 1 The drive was told to write its factory default settings.
  • A reset to defaults from the keypad, software or network
  • Clear the fault or cycle power
  • Re-enter the parameters the application needs
F059Safety OpenType 1PowerFlex 525 only Both Safe Torque Off inputs (Safety 1 and Safety 2) are off.
  • The machine's safety circuit opened (an e-stop, a guard, a safety relay)
  • On a drive that does not use Safe Torque Off: the S1 / S2 / S+ jumper is missing or loose
  • Find out why the safety circuit opened and reset it the way the machine's procedure says
  • Never jumper out a safety circuit that is in use
  • Only where the drive does not use Safe Torque Off: check that the factory jumper on S1, S2 and S+ is in place and tight
  • This fault is turned on with t105 [Safety Open En]
F063SW OverCurrentType 1 Current stayed above the programmed shear-pin level for longer than the shear-pin time.
  • A jam or a sudden mechanical overload
  • Shear-pin level or time set too tight
  • Check the connection between motor and load and the machine itself
  • Check A486 / A488 [Shear Pin x Level] and A487 / A489 [Shear Pin x Time]
F064Drive OverloadType 2 The drive's own overload rating was exceeded.
  • Load too high for the drive's rating
  • Acceleration time too short
  • Reduce the load or lengthen the acceleration time
  • Compare the motor's current with the drive's rating
F070Power UnitType 2 The drive detected a failure in its power section.
  • Temperature around the drive above its rating
  • An internal power-section fault
  • Check the ambient temperature
  • Cycle power
  • The manual says to replace the drive if the fault cannot be cleared
F071DSI Net LossType 2 Control over the Modbus or DSI link was lost.
  • A loose or damaged communication cable
  • Wrong Modbus / DSI settings
  • The master device stopped communicating
  • Cycle power
  • Check the communication cabling
  • Check the Modbus or DSI settings and status
F073EN Net LossType 2PowerFlex 525 only Control through the built-in EtherNet/IP port was lost.
  • A cable, switch or network problem
  • Wrong EtherNet/IP settings
  • The controller stopped its connection
  • Cycle power
  • Check the Ethernet cabling and switch
  • Check the EtherNet/IP settings and the network status
F081DSI Comm LossType 2 Communication between the drive and its Modbus or DSI master was interrupted.
  • A cable problem or electrical noise
  • Wrong communication settings
  • A failed master device
  • Cycle power and check the cabling
  • Check the Modbus or DSI settings and status
  • The drive's reaction is set by C125 [Comm Loss Action]; the manual also suggests grounding I/O terminals C1 and C2 for better noise immunity
F100Parameter ChksumType 2 The drive's stored parameter memory is corrupt.
  • Corrupted parameter storage
  • Reset to factory defaults with P053 [Reset To Defalts] = 2 “Factory Rset”
  • Then re-enter the application's settings (a saved copy of the parameters helps)
F111Safety HardwareType 2PowerFlex 525 only A fault in the Safe Torque Off input hardware: only one of the two safety inputs is on.
  • One safety channel open (wiring or a safety device fault)
  • On a drive that does not use Safe Torque Off: a loose S1 / S2 / S+ jumper
  • A control module fault
  • Check both safety input signals
  • Only where the drive does not use Safe Torque Off: check that the factory jumper is in place and tight
  • The manual says to replace the control module if the fault cannot be cleared
F114uC FailureType 2 The drive's microprocessor failed.
  • Electrical noise or poor grounding
  • A control module fault
  • Cycle power
  • Check the grounding against the manual's grounding requirements
  • The manual says to replace the control module if the fault cannot be cleared
F122I/O Board FailType 2 A failure was detected in the drive's control and I/O section.
  • A control or I/O board fault
  • Cycle power
  • The manual says to replace the drive or the control module if the fault cannot be cleared

The fault name is the short text the drive shows. Rarer codes in the same manual chapter that this page doesn't cover: F009, F072, F080, F082, F083, F091, F094, F101, F105, F106, F107, F109, F110, F125, F126, F127 – see the manual for those.

Source: Rockwell Automation, PowerFlex 520-series Adjustable Frequency AC Drive User Manual, publication 520-UM001O-EN-E (September 2025) – Chapter 4, Troubleshooting: Fault Types, Descriptions, and Actions, read on October 17, 2026.

Meanings, causes and checks are summarized in our own words. The manual is the reference: it has every code, the full corrective actions and the safety instructions. A newer revision of the manual may add codes, so check the current revision for your drive.

Allen-Bradley AC drives in stock

We have no PowerFlex 525 in stock right now. These are other Allen-Bradley AC drives on our shelves; for a PowerFlex 525, send us the catalog number and we'll check our sourcing network.

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  • 20-COMM-PAllen-Bradley 20-COMM-P Series A PROFIBUS DP Adapter PowerFlex Drive Module
  • 20AD3P4A3AYYNDNNAllen-Bradley 20AD3P4A3AYYNDNN PowerFlex 70 VFD 2HP 480V 3.4A with HIM Keypad
  • 20D-DL2-ENET0Allen-Bradley 20D-DL2-ENET0 Spare Parts Kit Ethernet Comm Module PowerFlex 700S
  • 22A-D6P0N104Allen Bradley 22A-D6P0N104 SER A 3 Phase, 380-480V,48-63Hz

Fault won't clear?

When the checks point to the drive itself – the manual's “replace the drive” or “replace the control module” – send us the fault code and the catalog number from the nameplate. We check our shelves and our sourcing network and reply with a written quote. Purchase orders are welcome; payment is due before we ship.

Frequently asked questions

How do I clear a fault on a PowerFlex 525?

Press Esc to acknowledge it, fix what caused it, then clear it: press Stop (when P045 [Stop Mode] is 0 to 3), cycle power, set A551 [Fault Clear] to 1, or use a digital input set to Clear Fault. A fault comes straight back if its cause is still there.

What is the difference between a Type 1 and a Type 2 fault?

A Type 1 fault can be reset by the drive's auto restart (A541 [Auto Rstrt Tries] and A542 [Auto Rstrt Delay]) once the condition is gone. A Type 2 fault is never auto-reset: it points to wiring, programming or hardware, and the cause has to be fixed before it can be cleared.

Where can I see which faults a PowerFlex 525 had?

b007 [Fault 1 Code] holds the most recent fault, b008 and b009 the two before it, and F604 to F610 go back to the tenth. A fault that repeats is recorded once.

Do these fault codes apply to the PowerFlex 523?

Mostly yes: the PowerFlex 523 and 525 share one user manual and one fault list. Load Loss (F015), Safety Open (F059), EN Net Loss (F073), EN Comm Loss (F083), Encoder Loss (F091) and Safety Hardware (F111) are PowerFlex 525 only.

Can you supply a replacement PowerFlex 525 drive or control module?

Send the catalog number from the nameplate and the fault code through our quote form. We check our shelves and our sourcing network and reply with a written quote.

Send us the fault code

Tell us the code and the drive's catalog number – we'll check our shelves and our sourcing network for a replacement and quote it in writing.

Send the code & catalog number Request a drive quote

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