235-00A5

Identify Swapped Modules

Check alarm display parameters %1 and %2 to identify which module types are swapped and their current vs. expected slot positions.

Write down the module serial numbers before moving them to avoid confusion

Power Down System

Execute emergency stop and power down the complete TNC system including I/O racks before handling any modules.

Never remove or insert I/O modules with power applied - this can damage the HSCI communication interface

Swap Modules to Correct Positions

Remove the two identified modules and install them in their correct slots according to the hardware configuration documentation.

Check module part numbers against slot configuration before powering up

Verify Installation and Restart

Power up system and verify alarm clears during HSCI initialization sequence in the startup diagnostics.

Monitor the PLC status display during startup to confirm all modules are recognized correctly

Access Hardware Configuration

Navigate to MOD function, select 'Hardware Configuration' and review the I/O module setup for HSCI address %3 shown in alarm.

Compare configuration with physical rack layout documentation

Verify Physical Module Layout

Document actual module types and positions in the I/O rack, noting part numbers and slot positions from left to right.

Ensure proper ESD protection when inspecting modules closely

Update Configuration Parameters

Modify the hardware configuration to match actual physical module positions, ensuring module types correspond to correct slots.

Save configuration to backup before making changes

Restart and Validate

Perform complete TNC restart and verify HSCI communication establishes without errors during initialization.

Check I/O status in PLC program to confirm all modules are functioning correctly

Inspect HSCI Cable Connections

Check all HSCI communication cables at the I/O rack for secure connections, proper seating, and cable integrity.

Power down system before disconnecting any HSCI cables

Test Cable Continuity

Use appropriate test equipment to verify HSCI cable continuity and check for intermittent connections or damaged conductors.

Flex cables gently during testing to identify intermittent faults

Replace Suspect Cables

Replace any damaged HSCI cables with genuine HEIDENHAIN communication cables of correct length and specification.

Route new cables away from high-voltage motor cables to prevent interference

Verify Communication Stability

Monitor HSCI communication status over several startup cycles to ensure stable module recognition.

Check communication diagnostics in TNC service menus for error counters

Isolate Suspect Modules

Remove both modules identified in alarm parameters %1 and %2, and test each module individually in a known good slot.

Handle modules by edges only and use proper ESD protection

Test Module Identification

Install each module separately and verify the TNC correctly identifies module type and responds properly to HSCI communication.

Use TNC diagnostic functions to read module identification data directly

Replace Defective Module

Replace any module that fails to identify correctly or shows communication errors with genuine HEIDENHAIN replacement part.

Record module serial numbers and failure symptoms for warranty claims

Validate System Operation

Install replacement module and verify complete I/O system functionality through PLC program testing and machine operation.

Perform complete I/O point testing to ensure all functions work correctly