Powered
Electrical/control power is available. The machine may still be idle.
Interactive engineering guide
Measure the machine state that answers the decision.
“Runtime” can mean powered, running, loaded, productive, cycling, or something else. Define the state first, reuse trustworthy existing signals where possible, and add instrumentation only when the decision still cannot be answered.
Define the language
These states are not interchangeable.
Running
A defined machine motion or run state is active. It may not be loaded.
Loaded
The machine is doing work above a defined load threshold. It may still produce no good product.
Productive
The machine is producing acceptable output under the agreed definition.
Cycles
Discrete machine cycles or events are counted. One cycle does not automatically equal one good unit.
Downtime
A defined expected-production period is lost. Planned stops and non-scheduled time should not be mixed blindly.
Route selector
Start with the operating question.
This selector does not design a control system. It shows the minimum evidence route that is usually worth checking before new hardware is proposed.
Recorded-hours check
Check whether your recorded states are internally consistent.
This calculator uses only the hours you enter. It does not infer causes, production quality, planned time, or OEE.
Signal selection notes
Use the least intrusive trustworthy signal.
PLC/controller
Often the best starting point when an existing state is documented and actually represents the physical condition required.
VFD/drive status
Useful for commanded/run state, but it does not by itself prove load, material flow, or good production.
Auxiliary contact
Can indicate contactor/relay state. It may represent energisation rather than actual shaft motion or useful work.
Current or power
Can help distinguish off, idle, and loaded states after validation, but thresholds and operating variation can create ambiguity.
Cycle sensor/counter
Useful for discrete events where one verified event has a clear operational meaning; good output may still require a quality signal.
No existing signal
Observe the process first, define the state boundary, then specify the minimum sensing and data path required.
Safety boundary:
Do not open, modify, or instrument live electrical panels to obtain a runtime signal. Electrical
access, current sensing, PLC/VFD changes, industrial wiring, and machine-control modifications
require competent personnel, safe isolation, site procedures, and an appropriate change/acceptance
process.