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Open IOconfig Project

Launch the IOconfig software on the programming PC and open the current project file for this machine. Check the project tree for any devices showing warning or error symbols (typically yellow or red icons).

IOconfig will display visual indicators on incompletely configured devices - look for any icons that are not solid green checkmarks.

Verify Device Configuration Completeness

Select each I/O module and fieldbus device in the project tree. Ensure all mandatory parameters in the device properties dialog are filled in and show no warning messages. Pay special attention to module addressing, telegram configuration, and watchdog settings.

Common incomplete items include missing station addresses, unconfigured diagnostic parameters, or default placeholder values that need machine-specific data.

Compile Project and Check Output

In IOconfig, execute the project compilation (Build/Compile function). Review the output window for any errors or warnings that indicate incomplete configuration. Address all errors before proceeding.

Do not transfer projects with compilation errors - the control will reject them or generate this alarm.

Transfer Complete Project to Control

After successful compilation, transfer the complete IOconfig project to the TNC using TNCbackup or network transfer. Ensure the transfer completes fully and verify the file size matches the source. Reboot the control to activate the new configuration.

Use TNCbackup to save the complete configuration backup before transferring new IOconfig projects - this provides rollback capability if issues arise.

Verify GSD/EDS File Installation

In IOconfig, check the device catalog to confirm all devices used in your project have their description files installed. Look for missing device types or generic placeholders indicating missing device descriptions.

Device description files must match the exact firmware version of the physical hardware - version mismatches can cause this alarm.

Import Required Device Descriptions

Obtain the correct GSD or EDS files from the I/O module manufacturer's website (for the exact hardware revision installed). In IOconfig, use the 'Import Device Description' function to add these files to the device catalog.

Always download device descriptions from official manufacturer sources - corrupted or incorrect files will cause configuration failures.

Reassign Devices with Correct Descriptions

Replace any generic or placeholder devices in the IOconfig project tree with the properly described device types from the updated catalog. Reconfigure all device parameters and verify addressing remains consistent.

Document the exact hardware model numbers and firmware versions from the physical I/O modules to ensure perfect matching with device description files.

Recompile and Transfer Updated Project

Compile the updated IOconfig project with proper device descriptions installed. Check for successful compilation, then transfer to the control and perform a complete reboot to initialize with correct device configurations.

Review Physical I/O Hardware Installation

Document the actual I/O modules installed on the machine, including their physical position sequence, module types, and bus addresses. Compare this against the IOconfig project topology tree structure.

Power off the control before inspecting I/O modules to prevent electrical hazards - follow lockout/tagout procedures.

Access PLC Diagnostics in MOD Function

On the TNC control, press MOD key and navigate to PLC > Diagnostics. Review the detected hardware list to see which modules the control is actually finding on the bus versus what is configured.

The PLC diagnostics will show exact bus positions where configured modules are missing or unexpected modules are found.

Correct IOconfig Topology

In IOconfig, modify the project topology to exactly match the physical hardware installation. Add, remove, or reposition modules in the configuration tree to match reality. Ensure bus addresses and slot positions are correctly assigned.

Use the topology auto-detection feature if available in IOconfig - it can scan the bus and propose the correct configuration based on detected hardware.

Verify and Transfer Corrected Configuration

Compile the corrected IOconfig project and resolve any addressing conflicts. Transfer to control and verify in MOD > PLC > Diagnostics that all configured modules now show 'OK' status with no topology errors.