1
E-stop button latched or damaged
medCheckTwist/pull every E-stop station; continuity-check the NC contacts with the circuit isolated.
FixReset all stations; replace a mushroom head with a failed contact block.
ToolsMultimeter
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2
Interlock open — door switch, guard or remote permissive
highCheckTrace the safety string one terminal at a time to find where the circuit opens.
FixClose the guard / repair the switch. Never jumper a safety interlock to keep the machine running.
SafetyBypassing an interlock removes the protection that stops the machine with the panel open. Do not do it.
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3
Safety relay failed or needs a power cycle
medCheckCheck relay status LEDs against the manufacturer's fault table.
FixPower cycle; replace the relay if the fault pattern persists.
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4
Remote start/stop or plant DCS holding the machine off
lowCheckLook at the controller's remote-mode indication and the incoming permissive contact.
FixSwitch to local mode for testing; resolve the plant-side permissive.
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Safety
Lockout/tagout before opening enclosures. Verify zero energy. Bleed system pressure before opening any pneumatic connection.