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Danger! Unexpected machine start

Article#: 00119

Date: 2026-03-14

Author: Radim



A traffic light with both the green and red lights on

A machine may be stopped by conditions that have a higher priority than the PLC program controlling machine operation - for example by a safety function or by a fault. When this happens, the PLC program must also detect this stop and adjust its internal logic accordingly.

Because the PLC program previously issued commands to start the machine, it must reset or inhibit all active start commands or running sequences so that the machine cannot restart automatically once the cause of the stop has been removed - for example after a hazardous condition is cleared, the safety circuit is reset and closed, or an alarm is acknowledged.

Design the PLC program so that it detects a higher-priority stop and resets all active start commands and running sequences. Ensure that all state machines return to their passive states, where the program waits for a new start command. The machine must only resume operation after a deliberate new command, either from an operator pressing the start button or from a higher-level control system.

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