Did you try SFR?

solid think you said you were getting a C1 error code on the mcvinst5 board i sent you a message regarding this. I believe you said the error code on ims was 681 as well, so looks like it could be an encoder problem or interface between the 2. says encoder position is not being sent to or received from the drive.
indirtwetrust, if they find the problem, do you have to enter SFR command. does the RRF command take care of the TFR and SFR commands at the same time?

RRF resets a run monitor condition like brake switch, TFR is a tach fault reset but I think when you lose SAFE3 with the 681 you need an SFR. Unless your encoder pico fuse is blown though, it should reset and run. 681 faults tend to be intermittent and a pain in the ass. Usually comes down to noise and shielding, make sure the shielding ground is landed to the encoder interface card at the motor and not tied to actual ground there or in the controller or you will make a loop between the encoder and the interface card. The shield is grounded in the encoder itself and it can't be tied to ground anywhere else but needs to tie through the interface card to drain the whole cable. Make sure there is no exposed foil at the ends of the cable and the cable is routed as far as possible from any high voltage. The motor ground needs to be solid from the controller ground buss to the machine beams in the junction box and the shield on the motor lead cable lands at both ends to keep the noise in.

Thanks Vator and indirtwetrust. We only did TFR. After Vator's message and indirtwetrust's input, it is most likely the pico fuse. I ASSUMED we could still run on inspect or with the run bug after putting all jumpers in. The codes were 681 and 1021. I was sure it was in one of the inspect I/O's. We will be back this week and go through the encoder circuit.

Got to keep it simple!!!!

I will keep you updated.

This is a Synergy right? Ignore the 1021 unless it won't clear, then check inspect I/Os and bypass switches. If you get all your SAFE inputs and an 08 on the drive it should run.

It is a Synergy and the pico fuse was blown. It blew again once power was turned on. How do you run it without the encoder to replace the encoder or repair the wire?

We may have to drift the car.

I am nearly positive you will have to drift the car. May be a stray shield or something in the junction box with the absolute encoder interface card. If it is the encoder you will have to do an encoder alignment with a balanced load after you replace it.

You my want to try setting it up as if it were on temporary run. I still have some info. Pm me and I'll share it with you.

Update....
we found the absolute encoder interface board burned. Replaced it and after a few minutes the new one burned up. We have another one and encoder coming.

We did check for stray shields, the green and green/black wire that is not used was not touching anything.

What voltage do you have to the board and encoder? 5vdc? 24, 120 DC, any AC?

We were getting 24 volts to the board. Just got the info you sent me will double check that. The original board was the 6300xa1 as well as the new one.

We have replaced encoder and board. We are not blowing the pico fuse.

Still no Safe 3 input and have a fault code of C1 on the Drive.

No fault codes on IMS.

Any ideas?

So if you cycle power on inspection the drive says C1 before you try to move the car?

Yes,

C1 comes on before an attempt to run is made on inspection.