231-E019

Check Firmware and Safety Versions

Enter MOD mode, select 'System Information' and document the NC software version. Then navigate to 'Safety' submenu and record the Safety PLC version and configuration date. Compare these against machine documentation.

Safety configuration version must match or be compatible with NC firmware version - check Heidenhain technical documentation for compatibility matrix.

Access Safety Configuration Status

In MOD function, select 'Safety Configuration' then 'Status Display'. Look for red indicators or error messages. Note the configuration checksum displayed and compare with documented value.

Do not modify safety parameters without proper authorization and safety training - this may void machine certification.

Restore Compatible Safety Configuration

Using TNCbackup or Programming Station, restore the safety configuration files (.SPL, .SEC) from the backup matching your current firmware version. Files are located in SYS:\SAFETY directory.

Always maintain version-matched backup sets containing both NC parameters and safety configuration files together.

Perform Safety Configuration Validation

After restoration, in MOD mode navigate to Safety Configuration and select 'Validate Configuration'. The system will perform CRC check and compatibility verification. Power cycle after successful validation.

Safety validation requires machine in safe state with all axes referenced and safety circuits functional.

Verify Safety Directory Integrity

Boot control into Programming Station mode (if available) or use TNCbackup. Navigate to SYS:\SAFETY and verify presence of .SPL (Safety PLC program) and .SEC (Safety Security) files. Check file sizes against known good backup.

Use file properties to check modification dates - recent unexpected changes indicate possible corruption.

Check Storage Medium Health

In MOD function, access 'System Test' and run 'Storage Device Check' to verify IDE/CF card or SSD integrity. Look for bad sectors or read errors in system partition.

Storage medium failures can cause progressive data corruption - plan for immediate replacement if errors detected.

Restore Safety Files from Validated Backup

Using TNCbackup, restore only the SYS:\SAFETY directory from the most recent validated backup. Ensure backup was created when machine safety system was functioning correctly and certified.

Keep multiple dated safety configuration backups - restoration must use configuration matching both firmware version and machine mechanical configuration.

Clear Safety Configuration Cache

After file restoration, power off control completely for 30 seconds to clear configuration cache. Upon restart, SPLC will rebuild configuration from restored files.

Complete power cycle (not just NC reset) is required to ensure safety processor reinitializes completely.

Check EtherCAT Bus Diagnostic

Access MOD function, navigate to 'EtherCAT Diagnostics' and check bus status. Look specifically for FSoE slaves and verify 'Safety State' shows operational. Note any communication errors on safety-relevant slaves.

FSoE devices appear with distinctive safety icon in EtherCAT topology - they must show green status for SPLC communication.

Review TNCdiag Log for SPLC Errors

Using TNCdiag tool or in Programming Station, open diagnostic log and filter for 'SPLC' or 'Safety' entries. Look for entries timestamped at alarm occurrence. ERR-ID=%4 value will be detailed here with specific cause.

TNCdiag timestamp correlation with alarm occurrence pinpoints exact communication failure sequence.

Verify Safety Network Timing Parameters

In MOD mode under Safety Configuration, check 'FSoE Parameters' for cycle time settings and watchdog timers. Verify these match machine specification - incorrect timing causes telegram validation failures.

Do not modify FSoE timing parameters without consulting machine builder - incorrect values compromise safety system integrity.