PowerFlex 4, 40, 40P fault codes: F3, F5, F13, F33, F81

Q: How do I read the fault history on a PowerFlex 4 or 40?

Press Esc to regain the keypad, then read d007…d009 [Fault x Code]; d007 is the most recent fault (22A-UM001L p. 42, 22B-UM001J p. 48). On a PowerFlex 40P the history is in b007…b009, plus d310…d316 with FRN 3.xx and later (22D-UM001F pp. 50, 110–111).

The F codes shared by PowerFlex 4, 40 and 40P drives: meaning, Type 1 or Type 2, what to check and which codes exist on one family only; reading the fault history, clearing safely and planning the replacement — from 22A-UM001L, 22B-UM001J, 22D-UM001F.

A PowerFlex 4 (Bulletin 22A), PowerFlex 40 (22B) or PowerFlex 40P (22D) stops on a fault and shows the fault as F plus a number: the number flashes on the display and the FAULT indicator flashes red (22A-UM001L-EN-E p. 70; 22B-UM001J-EN-E p. 92; 22D-UM001F-EN-E p. 116). F5 is an overvoltage, F13 a ground fault, F81 a lost RS-485 (DSI) connection. The three families share most codes and the same fault types; where a code exists on only one family, or its meaning differs, this article says so with the page in each manual. The full tables are in chapter 4 of each user manual: PowerFlex 4 pp. 71–72, PowerFlex 40 pp. 93–95, PowerFlex 40P pp. 117–119.

How the fault shows and where to read the history

	PowerFlex 4 (22A)	PowerFlex 40 (22B)	PowerFlex 40P (22D)
Display	Integral keypad: all digits flash, FAULT indicator flashes red (pp. 37, 70)	Integral keypad, same behavior (pp. 40, 92)	Integral LED display: flashing fault number, FAULT indicator flashes red (pp. 45, 116)
Regain the display	Press Esc (p. 70)	Press Esc (p. 92)	Press the Up Arrow key (p. 116)
Fault history	`d007`…`d009` [Fault x Code] (p. 42)	`d007`…`d009` (p. 48)	`b007`…`b009` (p. 50), plus `d310`…`d316` [Fault 4…10 Code] with FRN 3.xx and later (pp. 110–111)
Firmware version	`d016` [Control SW Ver] (p. 44)	`d016` (p. 50)	`b016` (p. 52)
Modbus register for the fault code	8449 (p. 104)	8449 (p. 128)	8449 (p. 155)

In all three, the first fault-code parameter holds the most recent fault, and a fault that repeats is recorded only once. A PLC reading register 8449 with Function Code 03 gets the fault number in decimal; 0 means "No Fault".

The integral display of the PowerFlex 40P has a single key, the Up Arrow. For further programming and control the manual points to a DSI remote HIM or a PC tool such as Connected Components Workbench or DriveTools SP (p. 45).

Fault types and auto-restart

All three manuals use the same two types (PowerFlex 4 p. 69, PowerFlex 40 p. 91, PowerFlex 40P p. 115):

Type 1, Auto-reset/Run: if A092 [Auto Rstrt Tries] is above 0, the drive waits for A093 [Auto Rstrt Delay], then tries to reset the fault; if the cause has gone, it resets and restarts.
Type 2, Non-resettable: may need drive or motor repair, or comes from a wiring or programming error. Correct the cause before the fault can be cleared.

A092 ranges 0 to 9, default 0. A093 defaults to 1.0 s; its range is 0.0 to 300.0 s on the PowerFlex 4 and 40, and 0.0 to 120.0 s on the 40P (22A p. 60, 22B p. 73, 22D p. 77). With A092 above 0 and A093 set to 0, the drive clears an OverVoltage, UnderVoltage or Heatsink OvrTmp fault without restarting.

Auto-restart can start the motor without warning. Follow the plant's permit and lockout rules before you enable it.

Common fault codes

Type: 1 = auto-reset/run, 2 = non-resettable, "—" = no type printed for that code. Pages are listed PowerFlex 4 / 40 / 40P; "—" means the code is not in that manual's table.

Code	Name	Type	Usual cause	What to check	Pages (4 / 40 / 40P)
F2	Auxiliary Input	1	Auxiliary input interlock open	Remote wiring; comms program faulting the drive on purpose	71 / 93 / 117
F3	Power Loss	2	Differs by family, see below	Incoming line and input fuses	71 / 93 / 117
F4	UnderVoltage	1	DC bus below the minimum	AC line for low voltage or interruptions	71 / 93 / 117
F5	OverVoltage	1	DC bus above the maximum; high line, transients or motor regeneration	Line voltage; longer decel or a dynamic brake option	71 / 93 / 117
F6	Motor Stalled	1	Drive cannot accelerate the motor	Longer accel (`P039`…`A067`) or less load; current under `A089` [Current Limit]	71 / 93 / 117
F7	Motor Overload	1	Internal electronic overload trip	Motor load against `P033` [Motor OL Current]; `A084` [Boost Select]	71 / 93 / 117
F8	Heatsink OvrTmp	1	Heatsink above its limit	Blocked or dirty fins; ambient max 40 °C (IP30/NEMA 1/UL Type 1) or 50 °C (IP20/Open); fan	71 / 93 / 117
F12	HW OverCurrent	2	Output current above the hardware limit	Programming, excess load, `A084`, DC brake volts set too high	71 / 93 / 117
F13	Ground Fault	2	Current path to earth at one or more output terminals	Motor and output wiring for a grounded condition	71 / 93 / 117
F29	Analog Input Loss	1	Analog input set to fault on signal loss, and the signal is lost	Parameters; broken or loose input connections	— / 93 / 117
F33	Auto Rstrt Tries	2	Auto-reset failed for the number of tries in `A092`	Fix the original fault, then clear by hand	72 / 94 / 118
F38 / F39 / F40	Phase U / V / W to Gnd	2	Phase-to-ground fault between drive and motor	Drive-to-motor wiring, motor; replace the drive if it cannot be cleared	72 / 94 / 118
F41 / F42 / F43	Phase UV / UW / VW Short	2	Excessive current between two output terminals	Motor and output wiring for a short; replace the drive if it cannot be cleared	72 / 94 / 118
F48	Params Defaulted	—	Drive commanded to write default values to EEPROM	Clear the fault or cycle power; program the parameters again	72 / 94 / 118
F63	SW OverCurrent	1	`A098` [SW Current Trip] exceeded	Load requirements and the `A098` setting	72 / 94 / 118
F64	Drive Overload	2	Drive rating of 150 % for 1 minute or 200 % for 3 s exceeded	Reduce load or extend accel time	72 / 94 / 118
F70	Power Unit	2	Failure in the drive power section	Cycle power; replace the drive if it cannot be cleared	72 / 94 / 118
F71	Net Loss	—	Communication network faulted	Cycle power; cabling; adapter setting; external network status	72 / 94 / 118
F80	SVC Autotune	—	Autotune cancelled by the user or failed	Restart the procedure	— / 94 / 118
F81	Comm Loss	2	RS-485 (DSI) port stopped communicating	Port wiring, port expander, adapters; `A105` [Comm Loss Action]	72 / 94 / 118
F91	Encoder Loss	—	One of the two channels of a differential encoder missing	Wiring; encoder; see below	— / — / 119
F100	Parameter Checksum	2	Checksum read from the board does not match the calculated one	`P041` [Reset To Defalts] = 1	72 / 94 / 119
F111	Enable Hardware	—	Safe-Off board or enable circuit, see below	See below	— / — / 119
F122	I/O Board Fail	2	Failure in the control and I/O section	Cycle power; replace the drive if it cannot be cleared	72 / 95 / 119

On the PowerFlex 40 and 40P, A089 is named [Current Limit 1].

Where the families differ

F3 Power Loss: on the PowerFlex 4 the DC bus stayed below 85 % of nominal; check the AC line for low voltage or interruptions and the input fuses (p. 71). On the PowerFlex 40 it means excessive DC bus ripple; check the line for phase loss or imbalance and the input line fuse (p. 93). On the PowerFlex 40P it is either the DC bus below 85 % of nominal or single-phase operation detected (p. 117).
F29: PowerFlex 40 and 40P only. It trips only when A122 [Analog In Loss] = 1 "Fault (F29)". Signal loss means below 1 V or 2 mA; normal operation resumes at 1.5 V or 3 mA and above (22B p. 80, 22D p. 85).
F81: on all three, A105 = 0 "Fault" (default) gives F81 and a coast to stop, and A106 [Comm Loss Time] defaults to 5.0 s (22A p. 63, 22B p. 76, 22D p. 80). The 40P table adds one step: connecting I/O Terminal 04 to ground may improve noise immunity (p. 118).
F91 (40P only): check the wiring. If P038 [Speed Reference] = 9 "Positioning" and E216 [Motor Fdbk Type] = 5 "Quad Check", swap the encoder channel inputs or any two motor leads; if the fault remains, replace the encoder (p. 119). The Modbus list on p. 155 shows "Encoder Loss Fault" as value 94, not 91.
F111 (40P only): DriveGuard Safe-Off (Series B) board installed with the ENBL enable jumper still in place: remove the jumper and cycle power. A failed Safe-Off board: remove power and replace the board. Failed hardware enable circuit: replace the drive (p. 119).

Checks, step by step

Record before you reset: the F number, the fault history, the firmware version and what the machine was doing.
Supply (F3, F4, F5): check the incoming AC line for low or high voltage, interruptions and transients, and the input fuses; on a PowerFlex 40 with F3, also phase loss or imbalance. F5 can also come from motor regeneration: lengthen the decel time or fit a dynamic brake option.
Load and current (F6, F7, F12, F63, F64): use the check in the table row for that code; A084 [Boost Select] appears under F7 and F12.
Ground and short (F13, F38–F43): inspect the motor and the output wiring. For F38–F43 the table adds: replace the drive if the fault cannot be cleared.
F8: clean the heatsink fins, check the cabinet temperature and the fan. F71, F81: cabling, adapter setting, network status and A105.

Clearing faults safely

Correct the cause first. Then clear the fault (22A p. 70, 22B p. 92, 22D p. 116):

PowerFlex 4 and 40: press Stop if P037 [Stop Mode] is 0 to 3; cycle power; set A100 [Fault Clear] to 1 or 2; or cycle a digital input set to 7 "Clear Fault" (A051…A052 on the 4, A051…A054 on the 40).
PowerFlex 40P: press and hold the Up Arrow key for 3 seconds; cycle power; set A100 to 1 or 2; or cycle a digital input A051…A054 set to 7 "Clear Fault".

A100 = 2 "Clear Buffer" also erases the fault history, on the 40P including d310…d316 (22A p. 62, 22B p. 75, 22D p. 79). Stop the drive before changing A100.

Clearing a fault can restart the motor. Follow the plant's permit and lockout rules. Before working inside the drive, isolate the mains and wait three minutes for the capacitors to discharge; a dark display does not mean the capacitors are discharged (22A p. 9, 22B p. 9, 22D p. 9).

When it is hardware

The tables point to drive replacement when F38–F43, F70 or F122 cannot be cleared; F81 may need new wiring, a port expander, an adapter or a complete drive; F111 on a 40P may need a new Safe-Off board or drive. The PowerFlex 40P manual states the drive has no user-serviceable components: do not take the chassis apart (p. 115).

Planning the replacement

TDL's end-of-life pages list these drives as discontinued by Rockwell on 30/06/2025, for example 22A-D2P3N104 (replacement 25A-D2P3N104), 22B-D010N104 and 22D-D010N104 (both 25B-D010N104). A fault that points to hardware is a good moment to plan the change: see PowerFlex 4/40 to PowerFlex 525 migration, and once the new drive is in, PowerFlex 525 fault codes. Need an engineer on site: request support.

Frequently asked questions

How do I read the fault history on a PowerFlex 4 or 40?

Press Esc to regain the keypad, then read d007…d009 [Fault x Code]; d007 is the most recent fault (22A-UM001L p. 42, 22B-UM001J p. 48). On a PowerFlex 40P the history is in b007…b009, plus d310…d316 with FRN 3.xx and later (22D-UM001F pp. 50, 110–111).

What does F3 Power Loss mean on a PowerFlex 40?

On the PowerFlex 40 it means excessive DC bus ripple: check the line for phase loss or imbalance and the input line fuse (p. 93). On the PowerFlex 4 and 40P, F3 means the DC bus stayed below 85 % of nominal, and on the 40P also single-phase operation (pp. 71, 117).

What is fault F81 on a PowerFlex 4, 40 or 40P?

F81 Comm Loss means the RS-485 (DSI) port stopped communicating; it is a Type 2 fault. The response is set in A105 [Comm Loss Action], default 0 "Fault", and the wait in A106, default 5.0 s.

How do I reset a fault on a PowerFlex 40P?

After correcting the cause, press and hold the Up Arrow key for three seconds, cycle power, set A100 [Fault Clear] to 1 or 2, or cycle a digital input set to 7 "Clear Fault" (p. 116). Clearing a fault can restart the motor, so follow the plant's lockout rules.

Sources

Rockwell Automation, 22A-UM001L-EN-E, PowerFlex 4 Adjustable Frequency AC Drive User Manual, 09/2024 — chapter 4 pp. 69–72; pp. 9, 37, 42, 44, 60, 62, 63, 104
Rockwell Automation, 22B-UM001J-EN-E, PowerFlex 40 Adjustable Frequency AC Drive User Manual, 09/2025 — chapter 4 pp. 91–95; pp. 9, 40, 48, 50, 73, 75, 76, 80, 128
Rockwell Automation, 22D-UM001F-EN-E, PowerFlex 40P Adjustable Frequency AC Drive User Manual, 09/2024 — chapter 4 pp. 115–119; pp. 9, 45, 50, 52, 77, 79, 80, 85, 110–111, 155

Read 13 November 2026. This article paraphrases the sources and does not quote them; read the original documents before designing or working on a system. Links open the latest edition in Rockwell's literature library; page numbers refer to the edition cited.