Leviton Zw4SF Fan Controller: goes completely dead a few times/year (Ernies driver, but even local switch control dies)

So I've been running the ZW4SF Leviton fan controller for a few years now; I added Hubitat control via Ernie's driver shortly after installing it. A few times a year, the switch/controller just goes dead. No control at all (via Hubitat or local switch). Clearly not a Hubitat driver issue since the local manual switch control also dies.

Took me a few times to establish the pattern and that all other avenues will not restore operation.

An Airgap reset (AKA, throw the panel breaker to cut power to the circuit ) and then restore it fixes it immediately... It's then good for 4-6 months before it dies again.

Anyone else seeing this? Annoying since there is no way to detect it, aside from user feedback: "Dad, the ceiling fan died."

I'll take the dad points for being able to magically fix the issue when it occurs, but just wondering if anyone else has seen this.

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I have 4 of those ZW4FS fan controllers. They all eventually go catatonic but like you stated, pulling the bar and putting it back down fixes it. Even happens to devices which have not been used between resets. Happens to the ZW6HD dimmers too and before the Levitons that would happen to my WEMO dimmers also. I suspect utility transients.

I have two of them on ceiling fans and they both become unresponsive via HA and locally.
It all depends on the type of failure, but I have noticed a few different types of failures....

  1. only the pilot light is on
  2. the speed light is on and none of the others
  3. NONE of the lights are on.
    There doesn't seem to be a pattern or circumstance that makes these fail, but a air gap switch off and on "resets" it and it starts working again..... for a while.
    I am using ernies driver also, but it is not due to the driver as I started with the generic driver and it still failed....
    I need to dig into the switch with a scope and log what the power supply is doing for starters.

OK, thanks for confirming; its not like its a bad /failed unit (or they all are), seems like some kind of design flaw.
I've got three leviton zwave dimmers (DZ6HD) in the same switch box and on the same AC circuit... and never a problem out of these (ever).

These ZW4SF are specifically supposed to handle the inductive load of the fans, but I wonder as this could be some kind of latch up condition and the processor goes out to lunch.

I think you are correct that the processor locks up in different states, but they are all non operational.
One thing I did notice that SOMETIMES locks them up is if you put the HE hub in zigbee inclusion mode for something that you are adding, it puts the zw4sf in lala land, even though the control is NOT in inclusion mode.
There doesn't seem to be any repeatable situation that this happens though....Strange!

Thanks for observation; although I have zero zigbee devices and my zigbee radio is disabled.

Also a quick note...
If the fan controller is not included with HE, it doesn't seem to have the lock up problem!
When the fan controller IS included, that is when the lock ups start.
Strange!