Allen-Bradley
Allen-Bradley PowerFlex VFD Repair (525 / 40 / 70 / 700 up to 25 HP) — Mail-In
Component-level repair for Allen-Bradley PowerFlex variable frequency drives up to 25 HP: 525, 523, 40, 4M, 70, and 700 series. IGBT modules and bus capacitors are the classic failures. Free evaluation, typical repairs $350–$900.
Coverage: PowerFlex 523 / 525 · PowerFlex 4 / 40 / 4M · PowerFlex 70 / 700 — up to 25 HP
✓Fixed — or it's free
Unrepairable units are refunded; evaluations cost $0
✓24-month warranty
Every repair covered, parts and labor
✓3–5 business days bench time
Rush (1–2 day) and emergency service available
✓Program preserved
Your application and settings stay in the unit
Symptoms this repair fixes
- ✓F004 / F005 / F012 class faults (undervolt, overvolt, overcurrent)
- ✓Dead drive — no display
- ✓Trips breaker at power-up
- ✓Output phase loss / motor won't turn
- ✓Dead keypad or display
Honest limits
- ✕Drives over 25 HP (declined at launch — full load validation requires capacity we don't claim yet)
- ✕Motor-side faults (identified at evaluation)
What you get
- ▸Free evaluation and firm quote
- ▸IGBT module replacement with new components
- ▸DC bus capacitor replacement
- ▸Precharge, control board, and keypad repair
- ▸Powered functional test with motor load appropriate to frame size
- ▸24-month warranty
Common catalog numbers we see
Part-number pages for this service
What to ship
- ▸The drive only — no cables
- ▸Fault code + HP/voltage + what tripped it
Full packing guidance: mail-in instructions.
Ship your unit to
USPS
Control Board Lab
PO Box 120241
Arlington, TX 76012
UPS / FedEx
Control Board Lab
1009 Oakwood Ln # 120241
Arlington, TX 76012
Write your RMA number on the outside of the box and include it on a note inside. Units over 50 lb (large VFDs, spindle drives, industrial PCs in enclosures) ship by freight — contact us before ordering and we will arrange dock-to-dock shipping.
Frequently asked questions
A new PowerFlex 525 is only a few hundred dollars more than a repair — why repair?
Sometimes replacement IS the right call, and we'll tell you when it is. Repair wins when lead time matters (drives can be weeks out), when your drive carries a configured parameter set your team doesn't want to rebuild, or on the larger frames where new pricing jumps into four figures.
Why only up to 25 HP?
Above ~25 HP, honestly validating a repair needs three-phase load-bank capacity. We publish the boundary instead of quietly under-testing big drives. As the lab's test capacity grows, the ceiling will move — check back or ask.
Start with a free evaluation
Ship it in, get a firm quote, approve before any work — pay nothing if it can't be repaired.
The Fixed-or-Free Guarantee: if we can't repair it, you don't pay for the repair.
Call (817) 799-7332 · 📱 Text us a photo of your unit · Email repairs@controlboardlab.com