Hello everyone!

So I have to work on a project, where the customer required to use a Siemens HMI Unified Panel, which I never did, only basic and comfort, so I'm assuming it won't be much different (hopefully).

Haven't started the project yet, we're still discussing some requirements with the customer, however, one of them is something I never came across and I'm not sure if it possible, so I would like to see if anyone has ever done it.

Basically the customer wants the Administrator log in on the HMI to be protected, not only by standard password and username, but also by a key switch.

In simple words, what they want to happen is, key switch turns on an input and while that input is ON, user can log in as administrator if they want and have the correct credentials. On logged in, if they remove the key (input goes back to 0), user should automatically log off administrator and go back to Operator.

Has anyone did this before? Is it possible to be done?

Thanks in advance for your help!

I just graduated in Control Engineering, and I’m now focusing on industrial automation systems. During my studies I built a good background in Siemens PLCs and programming them in TIA Portal. I also studied SCADA systems using WinCC.

Here is my question: I want to work for automation and control companies, so what should my next step be? I want to improve myself and develop my career. What resources would you recommend for that?

I'm trying to restore the program to an archaic Omron PLC that was lost (likely due to battery depletion) from the data on an identical unit. Unfortunately, I'm just a locomotive mechanic / electrician, and programming Atari-era tech isn't my forte (although I did own an Atari at the time).

I'm trying to follow the instructions keystroke -by- keystroke, but I just get an error beep when I try to assign a file number. Maybe I'm supposed to input a preexisting file number? If so, how do I find it?

Anyway, if there's anyone here with experience working with dinosaurs, I'd be grateful for help.

Any ideas on what to add next? I was thinking about some push buttons, but feel free to suggest some ideas.

Hello community,

I'm working on a site that's using a Siemens ET200SP to control a process. There's a safety DO module, 6AG2136-6DC00-1CA0 that until now has been energizing two normal relays that power on some safety valves, the whole thing working properly until now. The client has changed some specs mid project, and those relays have been swapped by Schenider's XPSBAC14AP safety relays. I'm not the one who designed the electrical cabinets and hardware architecture.

So currently we have two safety outputs powering two XPSBAC14AP relays, the issue I'm running into is that the DO safety module of the PLC is in "Short-circuit to ground" error. When I try to ACK the safety program, the error stays on and the channels are passivated. If I disconnect the relays and rearm, the error is gone. If after rearming I reconnect the relays, it doesn't show the error anymore, and it allows me to energize the relays, but after a few minutes the channels are passivated again this time with a "Short-circuit to L+" diagnostic message.

I'm at a loss trying to understand what's going on and right now I'm unable to keep the relays active for more than a few minutes and having to "rearm" the DO safety module manually disconnecting and reconnecting the relays. The connection is pretty simple, just a safety DO connected to the A1 terminal of the relay, and the ground to the A2, same connection that was working with the previously (not safety) installed relay.

Does anyone have any clue about what is possibly happening here?

Kind regards!

There are any chance or any good soul that have some type of brute f0rc& to get the password of a Cp1H PLC? The company that produced the machine is already close and I cannot get in to troubleshooting because of password. Any good soul can help? Thanks

Hi,

I have a Siemens S7-1212C PLC and a SINAMICS V20 drive that I'm trying to communicate with using Modbus RTU. The purpose of this setup is to learn how Modbus communication works.

I'm having trouble establishing communication and reading the ZSW (status word) as well as writing the STW (control word). I believe the parameters and addressing are configured correctly in both the drive and the PLC.

When I attempt to send the STW, the MB_MASTER block remains busy for a while and then briefly goes to DONE, with no error messages or status codes reported.

I'm using a PROFIBUS connector suitable for RS-485 communication, and I have installed the termination resistor kit on the V20 drive.

So my question is: what could I be doing wrong? Has anyone experienced similar issues when setting up Modbus RTU communication between an S7-1200 and a V20 drive?

I've been following ERCOT's large-load growth pretty closely through my work in industrial power economics.

With all the data center expansion happening in Texas, I'm curious how much of that demand is actually reaching smaller engineering firms, controls integrators, and industrial contractors.

Are you guys seeing more projects from manufacturers expanding capacity, or is most of the new work coming directly from data centers?

Hey all

I want to get your two cents. I work for a CPG company and we've started to add safety interlocks for our line breaks in process, like flow panels and strainers. We use doors to completely cover access to the tri-clamp with a safety guardlock.

Our problem is that with guardlocks in the past, nuisance faults due to the redundant feedback having an issue during production can take us down. The problem is that if this happens once in the course of a month or two, based on our process design, it forces us to incur 6+ hours of downtime and/or dump a bunch of product that is exposed because a drain valve has to open and relieve pressure.

I've tried to negotiate the process with our external safety contractor, but they will not budge. We are using the TLS2 from Allen Bradley on a new project. My question for you is how well do these devices deal with vibration? In some areas we see very little, and in other areas we see a lot, but from previous experience we see that vibration is what really hurts us.

My idea is to break up the safety into two zones. One that isolates product in the pipe if the lock feedback creates a fault in our safety PLC, and another that uses a safety rated prox switch on our door which when lost will cause the dump valve to open the process to drain. My idea is that a safety (sil2) rated prox will be more dependable than a guardlock.

Title. I couldn't find an option for it in tia portal settings or anywhere else.
Many thanks in advance.

TLDR: This functionality seems to be hardcoded into the binaries and cannot be changed unless the dll are modified somehow. See edits below.

Edit: I've decided to check the tia binaries despite it being a search for a needle in a haysack for me since I'm not very knowledgable in these topics. I think I've found it in Siemens.Simatic.Hmi.Transfer.DownloadService.dll (V21), though I'm not sure if this piece of code is where the opening of the new tab triggers since it's also in the V18 dll but loading to a simulated project won't open a tab when using V18.

Processing img pujz41wi46yh1...

Edit2: Yes, I was correct in my assumption. I've debugged the tia process with dnSpy *FOR EDUCATIONAL PURPOSES\* and put a breakpoint at the OpenBrowser method. Then I've proceeded with the project load and the breakpoint activated after some time and I've confirmed that stepping over the this.ProcessWrapper.StartProcess(this.WebUrl); line indeed opens the browser.

Processing img hqsfzu62y6yh1...

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Help me please

Could someone please help me? I’m working on a term project that requires using the software Factory I/O (it’s not a game on Steam). I need to program a box-sorting station—which sorts boxes by weight—using the "Control I/O" language. (The station is already available in the software's built-in scenarios, but it isn't programmed yet.) I’ve been struggling with this for 2–3 weeks now and just can’t seem to get it to work. If anyone is able to help, please let me know! Below, I’ll show you the station itself and how I’ve attempted to program it so far.

,

Hey everyone,

I’m currently mapping out my long-term career path and looking for some real-world perspective or success stories from people who have actually made this jump.

Right now, I have a vocational certification in Electrical Installation and Maintenance (EIM), with a strong foundation in hardware, 3-phase systems, motor controls, switchgear, and electrical fault-finding. My immediate plan is to get hired as a field Industrial Electrician / Maintenance Tech on a factory floor to get solid experience with physical machinery and wiring.

While working on the floor, my goal is to heavily self-study PLC programming (focusing on Siemens TIA Portal, Ladder Logic, and troubleshooting/monitoring) with the ultimate goal of transitioning into a full-time PLC Programmer role.

For those who started on the tools and moved behind the laptop:

1. Did you find that your hands-on electrical troubleshooting background gave you an advantage over pure software/engineering graduates?
2. How did you handle the transition logistically? Did you learn on the job during downtime, or did you build a portfolio at home using simulation software?
3. What is the one thing you wish you knew or started studying earlier while you were still just pulling wires and swapping sensors?

Would love to hear any advice, pitfalls to avoid, or stories from anyone who successfully crossed the bridge from the tools to the code. Thanks!

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Hey everyone!

I wanted to share a control cabinet we've been working on and get some honest feedback from other automation engineers, PLC programmers and panel builders.

The entire automation system is programmed using Siemens TIA Portal V20, with WinCC Unified handling the HMI and graphical interface.

As you can see in the pictures, the cabinet includes:

- Siemens SIMATIC IPC industrial PC, installed in the upper section of the cabinet.

- PHASAK rack-mounted UPS for power backup.

- Siemens industrial power supplies and associated protection devices.

- Industrial communication and control equipment, including Ethernet/network connections.

- Circuit breakers, contactors, interface modules and terminal blocks, mounted on DIN rails.

- Cable ducts and separated installation areas for power distribution, control equipment and wiring.

- Rittal enclosure with an integrated cooling unit, providing thermal management for the installation.

- Additional space at the bottom of the cabinet for cable routing and future modifications.

The goal was to build a reliable, maintainable industrial automation system, with reasonably easy access to the components for troubleshooting and servicing.

I'd especially appreciate your feedback on:

1. Overall cabinet layout: Would you arrange the components differently?

2. Cable management: What do you think about the wiring, routing and accessibility?

3. Thermal management: Any concerns about component placement, ventilation or cooling?

4. Maintenance and future expansion: Does the design look practical from a technician's perspective?

5. General design quality: How does it compare with the control cabinets you normally see in your industry?

If you had to rate this cabinet from 1 to 10, what score would you give it, and why?

Constructive criticism is more than welcome. I'm particularly interested in hearing from people who work with Siemens PLCs, TIA Portal, WinCC Unified and industrial panel design.

Thanks in advance!

Hey everyone,

Just want to say that this subreddit has been extremely useful for a non-automation engineer to get my controly system started!

To all of you that are contributing here, Thank you! ❤️

A customer wants help obtaining Rockwell licenses for Factory Talk and Studio. When they went to Rexel for the licenses the rep at Rexel said Rexel was out of stock for the licenses and that CO should ask other vendors. Does this make sense? Does Rockwell only bless certain vendors with a limited number of software licenses?

Hello everyone
I have a degree in Computer Engineering, but for the past 2.5 years, I’ve been working as a CNC programmer/technologist.
In the future, I’d like to transition into PLC programming and industrial automation. I still have one year left on my current employment contract, and I’d like to use this time to learn as much as possible and prepare myself for the transition.
My question is: Would I be competitive in the job market after a year, even without previous professional experience in PLC programming or i will need more time?
I’d also appreciate any advice on what I should focus on during this year?
Would my Computer Engineering degree and CNC programming experience be an advantage when applying for PLC jobs?
I’d really appreciate hearing from people who work in PLC programming or have made a similar career transition.

Hey guys,

I've been tasked with setting up communications between an old MicroLogix 1000 and a PC with Ignition v7.9 HMI software on it. I've got a Digi One IAP handling the serial conversion, however everytime Ignition attempts to poll the PLC the serial converter just throws the packets away. I've contacted Digi about it and they say that my configuration is right, but they no longer support Allen Bradley DF1 conversion as of 2020.

Basically what i'm curious about is if there is a better product that has been successful in the past, or if i've just been dealt a fools errand because of how old the MicroLogix is. Thanks in advance folks.

Our design team is in the process of proposing the following design to our customer:

• PLC is Redundant ControlLogix 5580
• Firewalls are Fortigate FG-70F
• Access Switches are Stratix 5200 (1783-CMS10B)
• Distribution Switches are Stratix 5800 (1783-MMS10)
• Rapid-PVST Mode is being used on all switches to prevent loops.
• Primary Dist. Switch is Primary Root Bridge whereas Secondary Dist. Switch is Secondary Root Bridge.
• Fortigate Firewalls are in transparent mode with "stpforward enable" issued on uplink and downlink ports.

I have simulated the above on EVE-NG after which I see that if we use Fortigates in an HA configuration, whether it is Active-Active or Active-Passive, the Primary PLC will not be able to "see" the Secondary PLC and as a result of that, the two CPUs will remain in DISQ (disqualified) state.

Can someone please guide me if the same behavior will be exhibited on a live network? If yes, then how do we modify this design such that i) both PLCs remain "visible" to each other on the network and are able to attain the SYNC (synchronization) state, and ii) the HA link between the Fortigates is retained?

Alternatively, if I remove the HA link and configure both Fortigates as standalone firewalls, would it be considered as a "bad" design?

Hello everyone, looking for a quick sanity check. Is it
normal for these panelviews to not be able to ping them but still show up on rslinx? i just spend half a day troubleshooting my network and it was fine the whole time

Friday I installed a brand new IF8 card on this setup. I opened ControlFlash Plus to update the firmware on the card as I was instructed. When I confirmed my path and opened the backplane I only saw slot 4 recognized in the backplane. It was weird because every single card after Slot 1 had power except that one!!! Slot 1 wouldn’t turn on at all it was solid pitch black(green leds flashing as no project had been downloaded to the processor) I verified for voltage on my mod and sa terminal blocks and we are all good till there. I opened RSLinx to see if maybe I would see any faults on the backplane but nothing and I still only saw Slot 4 recognized in the backplane with slot 2 to 10 flashing. I went ahead and verified that slot 1 was seated correctly and it was. Would it be a device issue on Slot 1 that is causing the rest of the cards not being picked up in the backplane? I pulled Slot 1 off the processor and I didn’t see any damaged pins on the card or processor as well. Any troubleshooting suggestions would be appreciated. Thanks yall.

So here's my situation. I'm the field guy for about 40 S7-1200/1500 machines scattered across customer sites, most of them sitting alone in a cabinet with zero network access. And you know how it goes — customer techs "just tweaked a setpoint," local integrators "just fixed one little thing," and suddenly the program on the PLC is nothing like my backup and nobody admits to anything.

My problem: how the heck do I know if someone's been in the PLC since my last download?

The obvious answer is run the online/offline compare, right? But doing that block by block on every single visit, on 40 machines... yeah, not happening. And here's the part that's really bugging me — I've seen cases where the checksum comes back different, but when I actually dig in, the code is identical. Just some recompile nonsense, probably triggered by a firmware update via the Automation Tool or another PG doing a download. So now I don't even trust the checksum.

So my actual questions:

Bonus pain: a bunch of these machines have know-how-protected OEM blocks I can't even read back, so compare is a non-starter there.

How do you all deal with this? Even "I feel your pain, here's my workaround" answers are appreciated. Thanks!

I recently came across CODESYS Virtual Control and did some research into the technology stack behind it. From what I’ve seen, the architecture looks solid.

What I’m really interested in, though, is real-world implementation. Has anyone deployed CODESYS Virtual Control in an actual industrial process?

I watched one of their webinars where they claimed its performance was on par with hardware-based PLCs of similar specs. I’m curious to hear from people who have used it in production. How does it compare in terms of real-time performance, reliability, and overall stability?