140-0004

Identify the missing file

Note the exact filename displayed in the alarm where '%1' appears. Common missing files include CfgPgmCall.sys, CfgUserPath.sys, machine.cfg, or PLC-related .cfg files.

Take a photo of the alarm screen to capture the exact filename for reference during restoration.

Verify file location expectations

Access MOD function, navigate to TNC:\system\ directory and check subdirectories like TNC:\system\config\, TNC:\system\plc\, or TNC:\system\cfg\ depending on the missing file type.

Enable 'Show All Files' in MOD to see hidden system files that may not appear in normal file display.

Restore from recent backup

Access MOD > Backup/Restore, select a recent backup archive, and restore specifically the TNC:\system directory. Ensure the backup date predates the alarm occurrence.

Do not restore a full backup without verifying its integrity - this may overwrite current machine parameters.

Reboot and verify

Perform a complete control reboot (power cycle) after restoration and verify the alarm does not reappear during startup sequence.

Monitor the startup log in MOD > System Information > Log Files to confirm the configuration file loads successfully.

Check current software version

Access MOD > System Information > Software Status and record the NC Software version, PLC version, and build number. Compare against the expected version from your update documentation.

If version numbers show mismatches between NC and PLC components, this confirms incomplete update.

Review update log files

In MOD function, navigate to TNC:\system\log\ directory and open recent update log files (SysLog.txt or UpdateLog.txt) to identify failed file operations.

Search for 'ERROR' or 'FAILED' entries associated with the missing configuration filename.

Re-execute software update

Obtain the complete software update package from Heidenhain or your machine builder. Access MOD > Software Update and re-run the installation with the correct update file, ensuring uninterrupted power.

Ensure UPS backup power is active during update. Do not interrupt the update process as this can cause permanent file system damage.

Perform complete reboot cycle

After successful update, power down the control completely (not just NC reboot), wait 30 seconds, then power up and verify alarm clearance.

Clear the alarm history after successful reboot to confirm no recurring alarms during multiple startup cycles.

Access system initialization files

Via MOD function, navigate to TNC:\system\ and open TNC.SYS with the TNC text editor. Search for references to the missing filename identified in the alarm.

Make a backup copy of TNC.SYS before editing. Incorrect modifications can prevent control startup.

Verify path syntax

Check that all path references use correct TNC path syntax (e.g., TNC:\system\config\filename.cfg not C:\system\config\filename.cfg). Verify file extensions and capitalization match actual files.

Heidenhain paths are case-sensitive on some control versions. Ensure exact case matching.

Check CfgPgmCall.sys references

Open TNC:\system\CfgPgmCall.sys and verify all configuration file references point to existing files. Comment out (using ';' prefix) any references to non-existent optional files.

CfgPgmCall.sys often references custom machine configurations. Compare against machine builder documentation.