very good points, have had to toggle inputs in the PLC to unlatch a bit

You can toggle integers at the bit level if they are not being actively written to in the program. Like recipe parameters used for current job. They get written in once as job is loaded to run.

You can’t toggle actual inputs (i.e I:1, I:2) you can toggle binary bits (B:1, B:2)

I only force inputs and never force outputs. Forcing an output can bypass 40 required safety conditions that are not met. I would rather find which inputs i dont have on. Correct any correctable issues. Search out all uses in the program with a "find all" so you know exactly what it affects. Then decide between forcing the input if other uses wont cause an issue or branch around it using test mode.

How to fix i/o not responding?

Thanks for posting. Great info.

kokyd