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Access Service Mode

Power cycle the control while holding the MOD key to enter Service Mode. Select 'System Diagnosis' to access detailed startup logs and error information.

Service Mode bypasses normal startup procedures and provides direct access to system-level diagnostics unavailable in normal operation.

Review System Log Files

Navigate to TNC:\service\logfile.txt and examine entries around the time of last software update. Look for specific object names, DLL files, or system modules listed as missing or failed to load.

The logfile.txt will explicitly name missing objects - document these exact names for reload procedures.

Perform Complete Software Reload

Using TNCremoNT on a service PC, connect via LSV2 protocol and perform a complete system software installation selecting the 'Full Installation' option matching your control model (320/530/620/640). This overwrites all system files.

Always use software version matching your control hardware generation - check the IPC label for exact model before downloading software from Heidenhain portal.

Full software reload will reset machine parameters to defaults. Ensure you have MP backup file before proceeding.

Restore Machine Configuration

After successful software installation, restore machine parameters from backup file (*.bak or *.h) using TNCbackup utility or import via TNC:\system\ directory.

Keep dated backups of machine parameters taken during known good operation states for fastest recovery.

Boot to System Loader

Power on while holding MOD key, then select 'System Loader' from Service Mode menu. This provides access to low-level file system tools and diagnostics before full TNC OS loads.

System Loader operations can render the control unbootable if misused. Document all actions taken.

Run File System Check

In System Loader, select 'Check File System' to scan SYS: partition for errors. The utility will attempt automatic repair of file system inconsistencies. Note any reported bad sectors or unrecoverable errors.

Repeated file system errors or bad sectors indicate imminent CF/SSD failure requiring hardware replacement.

Test Storage Media Health

In Service Mode diagnostics, run 'Storage Media Test' to check CF card or SSD SMART status. Look for reallocated sectors, read errors, or wear indicators exceeding thresholds.

CompactFlash cards typically last 3-5 years in industrial use. Proactively replace if age exceeds 4 years or SMART warnings appear.

Replace Storage Media if Failed

If media tests show failures, power down completely, replace CF card or SSD with Heidenhain-approved media, then perform fresh software installation from System Loader using USB installation media.

Use only Heidenhain-approved industrial-grade CF cards or SSDs. Consumer-grade media will fail prematurely in CNC applications.

Identify Missing Configuration Files

In Service Mode, examine TNC:\system\ directory structure. Verify presence of critical files: sysconfig.sys, machine.cfg, plc.cfg, and axis configuration files. Compare against documented backup structure.

Standard TNC system directory should contain 15-25 files depending on options installed. Empty or sparse directories indicate file loss.

Restore from TNCbackup Archive

If recent TNCbackup archive exists (.bakx or .zip file), extract to USB drive, boot to Service Mode, and use TNCbackup restore function to recover system configuration files selectively or completely.

TNCbackup archives can be extracted on PC to examine contents before restore. Look for timestamp matching last known good operation.

Rebuild Configuration from Defaults

If no backup exists, copy default configuration files from TNC installation media or fresh install to a working directory, then customize with documented machine parameters (axis assignments, encoder types, PLC configuration).

Rebuilding configurations from scratch requires complete machine parameter documentation. Incorrect axis assignments can cause dangerous motion errors.