What causes fault code VFD-AUTOSTART1 (VFD Auto-Restart Fault — Retries Exhausted)?

Underlying fault is persistent — the condition that caused the original trip has not cleared. Intermittent fault occurring frequently — ground fault, power sag, or overload. Auto-restart delay too short — not enough time for condition to clear between attempts. Motor or cable insulation degrading — each restart attempt further stresses failing insulation. Mechanical issue on load side recurring — product jam reforms after each restart

How do I fix fault code VFD-AUTOSTART1?

Check VFD fault log — identify what fault code triggered each restart attempt. Address the root cause fault before resetting the auto-restart lockout. Increase time between restart attempts to allow more settling time. If ground fault, do not keep restarting — megger the motor and cable before clearing. Clear the lockout by cycling VFD power or using the fault reset input. Consider disabling auto-restart if the fault is potentially damaging (ground fault, overcurrent)

VFD Auto-Restart Fault — Retries Exhausted

VFD-AUTOSTART1

VFD attempted to auto-restart after a fault the configured number of times and all attempts failed. Drive has locked out and requires manual reset.

high vfd conveyor packaging

vfd auto restart lockout retry persistent fault

Probable Causes (ranked)

Underlying fault is persistent — the condition that caused the original trip has not cleared
Intermittent fault occurring frequently — ground fault, power sag, or overload
Auto-restart delay too short — not enough time for condition to clear between attempts
Motor or cable insulation degrading — each restart attempt further stresses failing insulation
Mechanical issue on load side recurring — product jam reforms after each restart

Fix Steps

1 Check VFD fault log — identify what fault code triggered each restart attempt
2 Address the root cause fault before resetting the auto-restart lockout
3 Increase time between restart attempts to allow more settling time
4 If ground fault, do not keep restarting — megger the motor and cable before clearing
5 Clear the lockout by cycling VFD power or using the fault reset input
6 Consider disabling auto-restart if the fault is potentially damaging (ground fault, overcurrent)

Field Trick

Auto-restart on a ground fault drive will kill the motor. Every restart attempt pushes current through the failing insulation, making it worse. If you see ground faults in the fault log, disable auto-restart immediately and fix the insulation issue.

Suggested Replacement Parts

Parts matched to fault category: Vfd

Allen-Bradley PowerFlex 525 AC Drive 1HP P/N: 25B-D2P3N114 1HP, 480V, 3-phase, built-in EtherNet/IP, EMC filter

AutomationDirect $395.00 Amazon $450.00 Grainger $520.00

ABB ACS580 General Purpose Drive 2HP P/N: ACS580-01-05A7-4 2HP, 480V, built-in safe torque off, adaptive programming

AutomationDirect $425.00 Amazon $480.00 Grainger $550.00

GS20 AC Drive 1HP (Budget Option) P/N: GS20-20P5 1HP, 230V, sensorless vector, compact size — good replacement for testing

AutomationDirect $149.00 Amazon $175.00

Prices are estimates. Verify part numbers match your equipment before ordering.

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