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Enter MOD function

Press MOD key, enter password if required, and navigate to machine parameters section

Changing machine parameters may affect machine safety functions. Document original values before making changes.

Check MP7200

Locate MP7200 (Number of digital outputs) and verify the value matches or exceeds the highest output number used in your PLC program for switch-off functions

Configure MP7210.x

Find the specific MP7210.x entry corresponding to the output number used for switch-off (x = output number). Configure the output with proper assignment to the physical hardware address and output type

MP7210 uses format: output number, hardware address, output type (0=standard, 1=safety). For safety switch-off functions, ensure proper type is set.

Cycle power

After saving parameters, perform a complete power cycle of the control (not just RESET) to ensure new output configuration is loaded into the PLC runtime

Access system files

Navigate to TNC:\system\ directory using file management (PGM MGT key). Locate SIK.SYS file and check file size and modification date

SIK.SYS should typically be several KB in size. A 0-byte file indicates corruption or incomplete configuration.

Review SIK.SYS content

Open SIK.SYS with the TNC editor or transfer to PC for review. Verify that all digital outputs used in PLC program are listed with correct module assignments and channel numbers

Restore or regenerate SIK.SYS

If SIK.SYS is missing or corrupted, restore from backup or use TNCopt configuration software to regenerate based on actual hardware configuration. Ensure all I/O modules are properly detected

Incorrect SIK.SYS configuration can cause safety system malfunction. Verify all entries against machine documentation and physical hardware before deploying.

Reload configuration

After correcting SIK.SYS, perform complete control restart (power cycle) to force reload of system configuration

Open PLC program

Access PLC > Edit PLC program and search for switch-off related markers (typically search for text strings like 'EMG', 'STOP', 'SWITCH' or examine outputs used in safety-relevant sections)

Common switch-off markers include M4003 (emergency stop acknowledge), M4000 (NC ready), or custom M markers defined by machine builder.

Identify output number

Note the specific M marker number or output number being used for the switch-off function. Cross-reference with PLC symbol table (if available) to determine intended hardware output

Verify marker assignment

Check PLC configuration section to confirm the M marker is properly assigned to a physical output. Navigate to PLC > Configuration > I/O Assignment and verify the mapping exists

Correct assignment or PLC code

Either add the missing output assignment in the PLC I/O configuration table, or modify the PLC program to use a correctly configured output marker. Ensure consistency between PLC code and configuration

Modifying safety-related PLC code requires thorough testing and validation. Follow machine builder's procedures for PLC modifications.

Test PLC program

Use PLC > Test mode to verify the output assignment works correctly before running in production. Monitor the specific output while toggling the PLC logic