I created a backup of the CF card from the PP65 panel using the Runtime Utility program. After restoring the backup to a new CF card and inserting it into the panel, everything seemed fine, but some functions didn’t work properly—for example, the manual carriage movement (forward/backward).
Could anyone please explain the correct procedure to create a reliable backup?
It’s hard to say, but considering you mentioned manual carriage movement, I assume you have motion component in your project, which depending on functionality used you may need to get the remanent/permanent variables (depending which one is used) from your old pp65.
Some information on how to get those variables values: List functions
That is strange, the PVI Transfer Tool will make a 1:1 copy and the PLC should see no difference between the two flash cards. Is the flash card from B&R or is this a consumer brand flash card?
There are ways to pull binaries from the PLC, but I would not recommend that because you might miss some data. Making a 1:1 copy is the way to go.
I would recommend to reach out to your local B&R office and see if you can get an B&R flash card. While it is odd that the project boots fine with a 3rd party flash card, there could be certain parts that are not readable for the PLC. The flash card most likely has 4 partitions. You could do a file compare to see if a file is missing on one of them.