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Identify the unplanned component

Record the component name (%1) and serial number (%2) from the alarm display. Common components include PLCxxxx (PLC module), CCxxxx (CC control unit), UMxxxx (drive modules), or IBxxxx (encoder interfaces).

Launch TNCopt commissioning software

Connect to the control using TNCopt (version must match control software version). Navigate to the hardware configuration section and perform a bus scan to detect all physically present components.

Update hardware configuration

In TNCopt, compare the scanned hardware against the project configuration. Accept the new serial number by either replacing the old component entry or adding the component if missing. Ensure all parameters and assignments are correctly transferred.

Before accepting changes, document the old serial number and save a backup of the current configuration file in case the new component needs to be reverted.

Save and transfer updated configuration

Save the modified hardware project in TNCopt and transfer the updated TNCopt.sys file to the control's SYS directory, overwriting the existing configuration file.

Perform cold start

Execute a complete system restart (power cycle or MOD → Reset → Cold Start) to force the control to reload the hardware configuration and reinitialize all components with the updated project.

Cold start will reset PLC program execution and clear certain system states. Coordinate with production before executing.

Check configuration file date

Access MOD → System Files and navigate to TNC:\system\. Check the date/timestamp of TNCopt.sys and compare against recent maintenance activities or software updates.

Locate correct configuration backup

Search for configuration backups in TNC:\backup\ or on external backup media. Look for TNCopt.sys files dated after the last known hardware change or component replacement.

Many sites maintain a configuration log book or service folder with dated backups. Check documentation for the most recent hardware configuration baseline.

Restore correct configuration

Copy the correct TNCopt.sys file to TNC:\system\ replacing the incorrect version. If no suitable backup exists, use TNCopt to perform a complete bus scan and rebuild the configuration from scratch.

Verify and restart

Before restarting, verify in TNCopt that all installed components match the configuration file. Perform a cold start to apply the corrected configuration and clear the alarm.

Identify the new component

Cross-reference the serial number in the alarm with recent hardware additions or expansions. Check installation documentation or service records for newly installed modules.

Open hardware project in TNCopt

Launch TNCopt and open the current hardware project. Navigate to the component tree structure showing all configured drives, I/O modules, and peripherals.

Add component to project

In TNCopt, add the new component to the appropriate section (drives, encoders, I/O, etc.). Use the automatic detection function or manually insert the component type matching the physical hardware. Assign all necessary parameters including bus address and functional assignments.

Use the 'Compare with actual configuration' function in TNCopt to automatically identify differences between the project and detected hardware.

Configure component parameters

Set all required parameters for the new component including scaling, monitoring limits, and functional assignments. For drives, configure motor parameters; for I/O modules, assign signal mappings.

Save and activate configuration

Save the updated TNCopt project and transfer to the control. Perform a cold start to activate the new hardware configuration with the additional component properly integrated.