231-A091

Physically inspect all safety devices

Check all safety doors, guard panels, and interlock switches are fully closed and mechanically engaged. Look for damaged door striker plates or misaligned switches.

Never bypass safety devices. Doing so violates safety regulations and may cause serious injury.

Check FSC input status in MOD menu

Press MOD key, navigate to 'System' > 'Safety' > 'FSC Inputs'. Verify all safety inputs show expected logic states (typically high/24V for closed/safe condition). Note which input is in fault state.

Input names in FSC menu correspond to PLC markers. Cross-reference with your machine's safety circuit diagram.

Reset safety circuit if necessary

Close all safety devices, then press the safety acknowledge/reset button on the machine (if equipped). Some machines require cycling mode selector to reset safety chain.

On machines with FSC, simple E-STOP reset is not enough—the safety circuit must acknowledge all devices are in safe state.

Clear alarm and test axis enable

Press CE key to clear alarm. Attempt axis motion in Manual mode. If alarm returns immediately, PLC logic or FSC configuration is preventing enable based on current safety state.

Verify all E-STOP buttons are released

Check every E-STOP button on machine, pendant, and operator panel. Twist and pull each button to ensure mechanical release. Look for damaged buttons that don't fully extend.

E-STOP circuits are series-connected. A single stuck button anywhere on the machine will lock all drives.

Check E-STOP input in PLC diagnostics

Press PLCPROGRAM key (or MOD > PLC > Diagnostics). Monitor the E-STOP marker (typically M4000 or similar per machine). It should show logic 1 when all E-STOPs are released.

The marker name varies by machine builder. Check PLC program or electrical documentation for exact marker assignment.

Reset control safety system

After confirming all E-STOPs are released, perform control reset: Press CE key to clear alarm, then press machine RESET button. On some machines, mode selector must be in specific position for safety reset.

If alarm clears but returns when attempting motion, the issue is FSC configuration or PLC logic, not the E-STOP hardware.

Test E-STOP circuit continuity

If software checks pass but alarm persists, measure 24VDC at safety relay outputs feeding X150 FSC inputs. Use TNCdiag > 'Signal diagnosis' to monitor FSC input voltage levels in real-time.

Only qualified electrical personnel should probe safety circuits. Improper testing can compromise safety system integrity.

Check FSC parameter status in MOD menu

Press MOD > 'System' > 'Safety' > 'FSC Configuration'. Look for warning messages indicating 'Parameter mismatch' or 'Configuration invalid'. Note any red-highlighted parameters.

FSC parameters are password-protected and CRC-checked. Changes require safety password and automatic validation cycle.

Compare machine parameters 7310.x

Enter machine parameter table (password required). Review parameter group 7310 (FSC configuration). Compare against machine documentation or backup file. Look for parameters showing default values instead of configured values.

Never change FSC parameters without proper authorization and safety validation. Incorrect settings can disable critical safety functions.

Restore FSC configuration from backup

If configuration is corrupted, restore from backup file: MOD > 'Data Transfer' > 'Restore Safety Parameters'. Select validated .SAF or .FSC file from TNC:safety directory or external media. Control will perform automatic validation.

After battery replacement, FSC parameters typically retain integrity, but CRC validation may fail. Reload configuration even if parameters appear correct.