Manual mode

6.3 Manual operation

The Manual operation is the operating mode in which the operator deliberately influences the model in order to establish defined states.

A central principle applies:

In manual mode the operator works on the model – not around the machine.

Manual mode is not an exception to the logic, but a another source of influence on the same model.

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Purpose of manual mode

The purpose of manual mode is to:

• deliberately reach defined states

• safely position machines

• enable commissioning and adjustment

• correct deviations in a controlled manner

It serves not for this purpose:

• bypass procedures

• test logic

• reduce safety

• force movements

Manual mode is controlled work, not a debug mode.

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Shared state space

Also in manual operation applies:

• every sequence is in exactly one state

• this state defines expectations (system layer)

• Monitoring remains fully active

The difference to automatic mode lies not in the model, but in who causes the change.

The state remains valid – only the source of the action changes.

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Working in manual mode

In manual mode the operator can:

• select states deliberately

• manually influence zones

• fulfil state conditions step by step

The following applies:

• States are not skipped

• Transitions occur not automatically

• every change is monitored

The process:

1. A state is active

2. The model shows which conditions are met

3. Deviations become visible

4. The operator deliberately acts on the affected zones

5. The state is fulfilled

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Visual feedback in manual mode

Manual mode relies on clear feedback.

Zones show their status immediately:

• Blue → the zone meets the expectation of the current state

• Red → the zone deviates from the expected behavior

This allows the operator to recognise at any time:

• which zone is relevant

• why a state is not fulfilled

• where targeted intervention is necessary

Manual mode does not show “what to press”, but “what is missing”.

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Monitoring in manual mode

All monitoring mechanisms remain active:

• Interlocks (i) protect the sequence

• CMZ protects system integrity

• State logic remains valid

There are:

• no weakened manual mode

• no tolerated deviations

• no temporary releases

Manual mode is not less strict – but more controlled.

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Distinction from automatic mode

To clarify:

• Automatic operation

  • System drives the process

  • state transitions occur automatically

• Manual operation

  • Operator influences zones

  • States are fulfilled manually

  • Transitions occur consciously

Both operating modes:

• use the same model

• are subject to the same supervision

• produce the same diagnostics

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Typical misconceptions about manual mode

Common misunderstandings are:

• ❌ “Different rules apply in manual mode”

• ❌ “Manual mode is debugging”

• ❌ “You can skip states”

• ❌ “Manual mode is less safe”

All of these assumptions are false.

Manual mode is the most controlled operating mode, because every deviation becomes visible.

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Summary

Manual mode:

• enables targeted work on the model

• makes deviations transparent

• remains fully monitored

• does not change the logic

Manual mode means: The person works in the model – not outside of it.