PowerFlex 40 Fault Codes on Alliance / UniMac Washer-Extractors
Last updated October 21, 2026
When an Allen-Bradley PowerFlex 40 drive (the inverter, VFD or motor controller) on a UniMac or other Alliance Laundry Systems washer-extractor stops the drum, it shows a fault code on its own display. This page puts each code next to what Rockwell’s PowerFlex 40 manual says it means and what Alliance’s washer-extractor drive manual tells technicians to check, so you can tell an outside cause — supply voltage, wiring, a binding basket, wrong parameters — from a drive that has actually failed.
One caveat first. Alliance says the PowerFlex drives in its equipment are custom-developed with their own features and parameters, and that parameter information in Allen-Bradley’s manual will differ and may not be relevant. Alliance’s drives report firmware 70.xx–90.xx; Rockwell’s manual covers its standard 1.xx–7.xx firmware. Treat parameter numbers in Rockwell’s actions (A098, P033 and so on) as Rockwell’s, not Alliance’s. Where the two manuals differ, this page shows both. Last verified October 20, 2026.
Reading and clearing a fault
- Where it shows. The drive’s display shows the code as soon as it trips, for example F005, and the digits flash while the fault is active. The fault status light flashes red.
- Fault history. The drive keeps its last three fault codes in display parameters d007 (most recent), d008 and d009. A fault that keeps repeating is stored only once. Check these before you clear anything.
- Clearing. Alliance’s manual is clear that resetting doesn’t fix anything: correct the cause first, then cycle power to the drive. The Stop key also clears a fault. Many codes clear on a power cycle and don’t come back until the drive runs again, so test a full cycle including extract.
- Useful readouts. d005 shows DC bus voltage, d024 drive temperature, and d030 how close the drive is to a motor overload trip (100% = F007).
Check these before you blame the drive
- Two DIP switches. Alliance warns that the Sink/Source switch must be set to SINK and the analog switch to 0–10 V on its equipment (as built when the manual was published). Set wrong, the drive won’t run and can be mistaken for a failed drive — check them on any replacement drive too.
- Drive-to-motor wiring. Loose or bad connections between the drive and motor create heat and extra current, and can show up as overcurrent faults and the max-retries fault (F33).
- The basket and belt. For stall, overload and overcurrent codes, Alliance’s checks are mechanical as much as electrical: does the basket turn freely, is the belt over-tensioned, is the motor or basket locked.
- Cooling. Alliance stresses clean air paths, closed cabinet doors and installed panels. Heat shortens drive life and causes F8.
- Parameters. Alliance’s troubleshooting manual lists drive faults 6, 7, 8, 12, 63 and 64 with the instruction to verify that the parameters loaded into the drive are correct, and for wrong parameters it points technicians to the drive’s programming decal.
PowerFlex 40 fault codes on Alliance / UniMac washer-extractors
| Code | What it means (Rockwell) | What Alliance says to check on washer-extractors | Rockwell’s listed action | Fault type (Rockwell) |
|---|---|---|---|---|
| F2 (display F002) | Auxiliary Input. The auxiliary input interlock is open. | Not in Alliance’s table. | Check remote wiring; verify communications programming for an intentional fault. | Auto-reset type |
| F3 (display F003) | Power Loss. Excessive DC bus voltage ripple. | “Power Loss Fault”: DC bus below 85% of nominal for more than 0.5 s. Monitor the incoming AC line for low voltage or power interruptions. | Monitor incoming line for phase loss or line imbalance; check input line fuse. | Non-resettable type: fix the cause, then clear |
| F4 (display F004) | UnderVoltage. DC bus voltage fell below the minimum value. | “Under Voltage Fault”: same as Rockwell. Monitor the incoming AC line for low voltage or interruptions. | Monitor incoming AC line for low voltage or line power interruption. | Auto-reset type |
| F5 (display F005) | OverVoltage. DC bus voltage exceeded the maximum value. | High voltage can come from motor regeneration; a buck transformer may be required. | Monitor AC line for high line voltage or transients. Motor regeneration can also cause it: extend decel time or install dynamic brake option. | Auto-reset type |
| F6 (display F006) | Motor Stalled. Drive is unable to accelerate the motor. | “Motor Stall”: motor stalled, load excessive. Check motor wiring and connection terminals, that the wash basket moves freely, and for excess belt tension. | Increase Accel Time (P039/A067) or reduce load so output current stays within A089 [Current Limit 1]. | Auto-reset type |
| F7 (display F007) | Motor Overload. Internal electronic overload trip. | Check motor wiring and connection terminals, basket freedom of movement and excess belt tension. d030 shows how close the drive is to this trip (100% = F007). | Reduce excessive motor load so output current stays within P033 [Motor OL Current]; verify A084 [Boost Select]. | Auto-reset type |
| F8 (display F008) | Heatsink OvrTmp. Heatsink temperature exceeds a predefined value. | “Over Temperature Fault”: clean blocked or dirty heatsink fins, check the ambient temperature and for a blocked or stopped fan. Keep cabinet doors closed and panels installed. | Check for blocked/dirty heatsink fins; verify ambient not above 40 C (IP30/NEMA 1) or 50 C (IP20/open); check fan. | Auto-reset type |
| F12 (display F012) | HW OverCurrent. Drive output current exceeded the hardware current limit. | “Overcurrent Fault”: check for a short at the drive output or excessive load at the motor. Loose drive-to-motor connections can also cause it. | Check programming; check for excess load, improper A084 [Boost Select], DC brake volts set too high, or other excess-current causes. | Non-resettable type: fix the cause, then clear |
| F13 (display F013) | Ground Fault. A current path to earth ground was detected at one or more drive output terminals. | “Ground Fault”: listed with the same description and no separate washer-specific action. | Check the motor and external wiring to the drive output terminals for a grounded condition. | Non-resettable type: fix the cause, then clear |
| F24 (display F024) | Unable to Decelerate (listed in Alliance’s table only; not in Rockwell’s standard table). | DC bus regulation is preventing deceleration, typically from high input voltage, motor regeneration or unstable motor operation. Check d005 is below 340 V (200–240 V machines) or 680 V (380–480 V), check for an imbalanced load, and check the speed steps through all extract speeds. | — | Alliance-only code |
| F29 (display F029) | Analog Input Loss. An analog input configured to fault on signal loss has lost its signal. | Not in Alliance’s table. | Configure with A122 [Analog In Loss]; check parameters; check for broken/loose input connections. | Auto-reset type |
| F33 (display F033) | Auto Rstrt Tries. Drive failed to reset a fault and resume running within the programmed A092 [Auto Rstrt Tries]. | “Max Retries Fault”: another fault must be corrected before the machine runs again. Loose or bad drive-to-motor wiring can show up as this fault. | Correct the cause of the fault and clear it manually. | Non-resettable type: fix the cause, then clear |
| F38 (display F038) | Phase U to Gnd. Phase-to-ground fault detected between drive and motor in phase U. | “Phase U Fault”: check the wiring between drive and motor and check for a grounded phase. | Check drive-to-motor wiring; check motor for grounded phase; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F39 (display F039) | Phase V to Gnd. Phase-to-ground fault detected between drive and motor in phase V. | “Phase V Fault”: check the wiring between drive and motor and check for a grounded phase. | Check drive-to-motor wiring; check motor for grounded phase; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F40 (display F040) | Phase W to Gnd. Phase-to-ground fault detected between drive and motor in phase W. | “Phase W Fault”: check the wiring between drive and motor and check for a grounded phase. | Check drive-to-motor wiring; check motor for grounded phase; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F41 (display F041) | Phase UV Short. Excessive current detected between output terminals U and V. | “UV Short Fault”: check the motor and external wiring to the output terminals for a short. | Check motor and drive output wiring for a short; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F42 (display F042) | Phase UW Short. Excessive current detected between output terminals U and W. | “UW Short Fault”: check the motor and external wiring to the output terminals for a short. | Check motor and drive output wiring for a short; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F43 (display F043) | Phase VW Short. Excessive current detected between output terminals V and W. | “VW Short Fault”: check the motor and external wiring to the output terminals for a short. | Check motor and drive output wiring for a short; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F48 (display F048) | Params Defaulted. The drive was commanded to write default values to EEPROM. | “Reset to Default Values”: verify or re-load the Alliance-specified parameters. Resetting the drive to defaults (P041) causes this fault and means it must be re-programmed. | Clear the fault or cycle power; program drive parameters as needed. | Type not marked |
| F63 (display F063) | SW OverCurrent. Programmed A098 [SW Current Trip] has been exceeded. | “Software Over-current”: instantaneous (100 ms) trip at the Alliance-specified maximum current. Check for a locked motor or basket, the correct motor/basket/pulley combination, and intermittent signals at the drive inputs. | Check load requirements and the A098 [SW Current Trip] setting. | Auto-reset type |
| F64 (display F064) | Drive Overload. Drive rating of 150% for 1 minute or 200% for 3 seconds exceeded. | Verify the parameters suit the motor and pulley combination, check for restricted basket rotation, and check for poor motor-circuit connections. | Reduce load or extend Accel Time. | Non-resettable type: fix the cause, then clear |
| F70 (display F070) | Power Unit. Failure detected in the drive power section. | Not in Alliance’s table. | Cycle power; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
| F71 (display F071) | Net Loss. The communication network has faulted. | Not in Alliance’s table. | Cycle power; check comms cabling, network adapter setting, and external network status. | Type not marked |
| F80 (display F080) | SVC Autotune. The autotune function was canceled by the user or failed. | Not in Alliance’s table. | Restart the procedure. | Type not marked |
| F81 (display F081) | Comm Loss. RS-485 (DSI) port stopped communicating. | Not in Alliance’s table. | If not intentionally disconnected, check/replace port wiring, port expander, adapters or complete drive; check connection; can be turned off via A105 [Comm Loss Action]. | Non-resettable type: fix the cause, then clear |
| F100 (display F100) | Parameter Checksum. Checksum read from the board does not match the calculated checksum. | Internal checksum mismatch: reset the drive to factory defaults, then re-load the Alliance-specified parameters. | Set P041 [Reset To Defaults] to option 1 'Reset Defaults'. | Non-resettable type: fix the cause, then clear |
| F122 (display F122) | I/O Board Fail. Failure detected in the drive control and I/O section. | Not in Alliance’s table. | Cycle power; replace drive if fault cannot be cleared. | Non-resettable type: fix the cause, then clear |
Code meanings and actions are paraphrased from Rockwell’s PowerFlex 40 user manual 22B-UM001J (Table 10) and Alliance’s drive manual F232120R7 (Table 20). Alliance’s table is abbreviated and Alliance points readers to the drive manual for the latest explanations. Codes marked “Not in Alliance’s table” are Rockwell’s standard meanings; Alliance doesn’t confirm them for its custom firmware.
Where the two manuals disagree
- F3 Power Loss. Rockwell describes excessive DC bus ripple (check for phase loss, line imbalance, the input fuse). Alliance describes the DC bus staying below 85% of nominal for more than half a second (check for low voltage or interruptions).
- F5 OverVoltage. Rockwell suggests a longer decel time or a dynamic brake. Alliance’s note is that high voltage can come from motor regeneration and that a buck transformer may be required.
- F24 Unable to Decelerate is in Alliance’s table but not Rockwell’s: check d005 is below 340 V on 200–240 V machines or 680 V on 380–480 V machines, look for an imbalanced load, and check the extract speed steps.
- F38–F43. Rockwell ends with “replace drive if the fault cannot be cleared”; Alliance’s actions for these codes stop at wiring and grounded-phase checks.
- F63 SW OverCurrent. Rockwell ties it to a programmable trip level; Alliance describes a 100 ms trip at the Alliance-specified maximum current and adds washer checks (locked motor or basket, motor/basket/pulley combination, intermittent input signals).
When is the drive itself the problem?
Neither manual says any single code proves a dead drive. Rockwell’s own actions say to replace the drive if the fault can’t be cleared for the phase-to-ground and phase-short faults (F38–F43), F70 Power Unit and F122 I/O Board Fail — and for F38–F43, Alliance sends you to the motor wiring and a grounded phase first. For everything else, work through the supply, wiring, mechanical and parameter checks above before condemning the drive — the no-spin troubleshooting guide walks through Alliance’s documented order.
If you do replace it, plan on programming. A new PowerFlex 40 doesn’t arrive with Alliance’s settings: resetting to defaults raises F048, and Alliance’s answer to F048 and F100 is to re-load the Alliance-specified parameters. Photograph the old drive’s nameplate and programming decal before you remove it, and match the exact catalog number — our Alliance / UniMac PowerFlex 40 cross-reference maps every Alliance drive part number to its Allen-Bradley catalog number. Weighing a PowerFlex 525 instead? Read the replacement & migration guide first.
Replacement drives we supply
New, unused, open-box surplus PowerFlex 40 drives for the 380–480 V Alliance positions below, with the cross-reference documented on each page. We confirm the match against your old drive’s nameplate before you pay.
- Alliance F8168602 → Allen-Bradley 22B-D6P0N104 (3 HP, 480 V)
- Alliance / UniMac F8169418 → Allen-Bradley 22B-D010N104 (5 HP, 480 V)
- Alliance F8168702 → Allen-Bradley 22B-D012N104 (7.5 HP, 480 V)
- Alliance F8168705 → Allen-Bradley 22B-D024N104 (15 HP, 480 V)
Not sure which drive you have? Look up a part number or send us the nameplate.
Sources
- Rockwell Automation, PowerFlex 40 Adjustable Frequency AC Drive User Manual, publication 22B-UM001J-EN-E (September 2025): fault types, clearing, and Table 10 fault descriptions — PDF
- Alliance Laundry Systems, washer-extractor AC drive information manual F232120R7 (April 2014): PowerFlex 40/400 section, display parameters, DIP switch settings, Table 20 drive fault codes — PDF
- Alliance Laundry Systems troubleshooting manual F8123401R2 (drive faults and parameters, p.28) — PDF
Alliance, UniMac and Allen-Bradley are trademarks of their respective owners. Thermal Harbor is an independent parts supplier, not affiliated with or authorized by Alliance Laundry Systems or Rockwell Automation. This page is a reference, not a substitute for a qualified technician: disconnect power and follow the machine’s safety instructions before working on a drive.