330-003C

Check Emergency Stop Status

Navigate to MOD > System > Safety > Emergency Stop Status and compare ES signal states between MC and CC modules.

Ensure all personnel are clear of machine before testing emergency stop circuits

Verify E-Stop Wiring

Check X1201/X1202 emergency stop input terminals on both SPLC modules for loose connections, corrosion, or damaged wiring.

Use a multimeter to verify 24V signal continuity through the entire E-stop chain

Test E-Stop Relays

Manually actuate each emergency stop button and monitor relay K1/K2 operation in the safety circuit diagnostics.

Only qualified personnel should work on safety circuits

Reset Safety System

After repairs, perform safety system reset via MOD > System > Safety > Reset Safety and verify alarm clearance.

Check Feedback Signal Status

Access MOD > System > Safety > Feedback Monitoring and compare FB_NCC signal states for all axes between MC and CC.

Look for intermittent signal dropouts that may indicate loose encoder connections

Verify Encoder Connections

Inspect encoder cable connections at X401-X4xx terminals on both SPLC modules and check for proper shield grounding.

Power down system before checking encoder connections to prevent damage

Test Communication Links

Use TNCdiag to test DRIVE-CLiQ or EnDat communication integrity between drives and safety controllers.

Check MP7300.x parameters for communication timeout settings if using EnDat encoders

Validate Safety Parameters

Verify MP7500.x safety monitoring parameters match between SPLC-MC and SPLC-CC configurations.

Diagnose Safety Switch Status

Navigate to MOD > System > Safety > Switch Monitoring and identify which KSW.x input shows state mismatch.

Use the safety diagnostic screen to see real-time switch states

Test Physical Switches

Manually operate each safety switch while monitoring X1301-X13xx input terminals on both SPLC modules for proper 24V switching.

Bypass safety switches only for testing purposes and restore immediately after diagnosis

Check Switch Wiring

Verify safety switch wiring integrity including proper dual-channel wiring for Category 3/4 safety switches.

Safety switches often require both NO and NC contacts wired to separate inputs

Validate Safety Logic

Review MP7200.x safety switch configuration parameters to ensure proper logic settings for each KSW input.

Check SPLC Communication Status

Access MOD > System > Safety > SPLC Status and verify communication link between MC and CC modules shows 'OK' status.

Look for communication error counters that indicate intermittent failures

Inspect Internal Connections

Check internal safety bus connections between SPLC-MC and SPLC-CC modules for proper seating and contact integrity.

Power down control completely before checking internal module connections

Verify Module Firmware

Check that both SPLC modules have matching firmware versions via MOD > System > Version Information.

Mismatched firmware versions can cause communication protocol incompatibilities

Reset Safety Communication

Perform complete safety system restart via MOD > System > Safety > System Restart to re-establish communication.

Monitor Safety Supply Voltage

Use MOD > System > Safety > Power Supply to check 24V DC supply voltage stability and current consumption.

Voltage should remain within 20.4V to 28.8V range under all load conditions

Check Power Supply Loading

Verify total current draw on safety 24V supply does not exceed rated capacity, typically 5A for standard SPLC systems.

Overloaded power supplies can cause voltage drops and erratic operation

Test Supply Ripple

Use oscilloscope to measure AC ripple on 24V DC safety supply - should be less than 5% peak-to-peak.

High ripple often indicates failing filter capacitors in the power supply

Verify Ground Integrity

Check safety ground connections and ensure proper isolation from machine ground to prevent ground loops.