swapped a dead powerflex 525 on the bag dump auger, 2hp, 480VAC. new one out of the box shows F059 Safety Open and won't start from the plc or the keypad. this machine has no safety circuit at all, just a stop pushbutton wired into the plc. old drive ran six years like that.
i loaded the parameters from the ccw file we keep for it, reset the fault and power cycled twice, and F059 comes straight back. keypad start does nothing either. bit out of ideas with it.
is the new drive bad out of the box? we have one more spare and it's the last one lol. or did the old one have a link in it somewhere that i've not carried over to the new one?
F059 isn't a parameter thing, so stop loading files at it. It's the safety terminals, nothing else. Look at the control terminal block on the new drive, S1, S2 and S+. Anything landed on them? And did the old drive have anything on those three?
nothing on S1 S2 S+ on the new one, all three empty. old drive is out in the truck, will look tomorrow.
wait. the old one had a little jumper piece across those i think. small plastic thing.
S1 and S2 are the two safe torque off inputs and each wants 24V from S+ before the drive will put out anything. No 24V, no torque, and with a run command sitting there it flags F059. From the factory those come linked with a jumper, if I remember right. Yours shipped without it or somebody borrowed it.
Drive off, locked out, terminal cover off. Link S+ to S1 and S+ to S2, a short wire does it. Only right because this machine has no safety function. If a safety relay ever stops that auger, its two outputs go on S1 and S2, one per channel, jumper out. Never jumper past a relay to get a line running.
found the jumper still on the old drive's terminal block in the truck. locked out, moved it over to the new one, S+ to S1 and S2. F059 gone, auger running from the plc.
so it was the sto inputs sitting open with nothing linking them, the drive was doing what it's supposed to and i spent two hours loading files at it.
thing i still don't get is why it faulted instead of just sitting there not running. the manual talks about the safety input but not that part. thanks eddie, ron.
Better it shouts than sits there quiet. Glad it was a 20 cent jumper.