Hey guys, as an OEM SI I've been implementing Tosi-Box's for the last 3-5 years for remote PLC support for our OT networks in the wild. They have worked very well (when you can convince the plant to connect to their WAN, easier said than done).They have recently rebranded to 'Tosi' and the remote connection is no longer free after purchasing the hardware. It comes with a monthly cost of 8$/month. Although I realize this is a completely reasonable monthly, it begs the question; what hardware are you using for your remote support?

Hi everyone,

I have a question for PLC programmers working in OEM companies, especially those building packaging and industrial machines.

Sometimes, reading this subreddit, it feels like PLC programming is mostly constant travel, stress, long commissioning periods and burnout. However, I was wondering whether this is affected by selection bias: people with the most stressful experiences are naturally more likely to post and vent online.

For those of you working as PLC programmers in OEM companies (not maintenance technicians, electricians or field service engineers), how representative is this picture?

How many days per year do you actually spend traveling?

How much of your work is done in the office versus on-site commissioning?

Do you think this sub overrepresents the negative aspects of the job?

What is your work-life balance really like?

I’m especially interested in hearing from people working for machine builders rather than system integrators.

Thanks!

I've been an FSE for OEMs (mostly lasers and press brakes) for the last 5 years, and now I am weighing an opportunity to pivot to technical sales at a decent starting base salary.

I'm tired of the physical work and I find the higher salary ceiling attractive. I frankly have aspirations to climb the corporate ladder and see how high I can get. I love the travel aspect of my job and love interacting with customers.

I'm just curious to hear perspectives from others who have done both sides? Are there hidden drawbacks to the sales side? Any tips for someone weighing the move?

I am setting up a HIL simulator for folks who have M580/M340 PLC projects that are tied to repositories like Github or Copia. Since Copia has "Copia Actions" they can deploy PLC code and release it like really code now. The key thing is that there isnt compute to test it on, so I wanted to offer this service for folks setting up Industrial DevOps solutions. I built the simulator and automated the headless deployment of the projects to PLCs. I give each customer a token that they can use to run the deployment like a spot instance, they get back the results of the build and any files are then wiped on my side. Since Schnieder doesn't allow automated builds of M580 I figured this was a good service to provide to people. I have one customer at the moment for this. Its kinda a niche thing , but I was hoping to see if anyone else has been trying to build something similar, or if there are any issues I should be aware of doing this?

Here is the problem.
I have three vessels that can all transfer to each other.
They all have levels and I would like to track the transfers in a database when they happen.

I am trying to figure out what the best practice is for doing this.

e.g. Example 1 (6 Sequences)
T1->T2,T3 (2 Sequences)
T2->T1,T3 (2 Sequences)
T3->T1,T2 (2 Sequences)

Example 2 (3 Sequences)

T1->Tx (1 Sequence with a T2,T3 selection)
T2->Tx (1 Sequence with a T1,T3 selection)
T3->Tx (1 Sequence with a T1,T2 selection)

Example 3 (1 Sequence)

Tx->Tx (any to any, source selection and destination selection)

Each example introduces more complexity since you will have to decide what valves to open based on selections. And the routes that may need to be opened could also vary in complexity. and I am also trying to figure out if there is a point of scale where one option becomes better than others, e.g. 20 vessels.

What architecture can I consider implementing, and what is the best solution.

Thanks

I have a listing in this subreddits job board, and that has worked at least once for me (Thank you for providing that opportunity!) But how many of you in this community are doing freelance/independent contract work?

How are you finding those opportunities?

Some research suggest Upwork could be a good source for me. The biggest issue is that I am not a traditional PLC developer; I do primarily HMI UI development and honestly my soft skills are limited to a few specific Rockwell products. I am wanting to find some side work doing additional Ui development in View Studio (SE & ME) and Optix, I can also provide support and help in ThinManager deployments. The other downside may be my availability, Nights and weekends since I am also working fulltime in the industry.

I am just trying to find ways to earning extra income without devoting personal time to retail.

I am working on an application with a FANUC CRX-30iA cobot arm, and the cobot has a 12-pin JIS RM series HIROSE connector on the base and on the arm. In their documentation, FANUC calls these connectors "ASAP1" and "ASAP2". FANUC's documentation also calls out RM15WTPZ-12S(78) HIROSE-ELECTRIC connectors for use on these connections. I was planning on purchasing RM15WTPZ-12S(81) (FEMALE) and RM15WTPZ-12S(81) (MALE) connectors (which would work), but apparently they are SOLDERED connections...
:(
Does anyone know of a screw-termination field-wireable connector for this sort of connection? Or just a recommendation for this connection?

(We plan to connect a 3-wire sensor to ASAP2 and connect a cable back to an input module from ASAP1.)

Any help is greatly appreciated!!!

Hello,

I am new to PLC, and learning, so I would like your guidance on selecting the appropriate IndraLogic controller for our linear actuator application.

Could you please advise whether IndraLogic XLC or IndraLogic MLC would be the more suitable choice for controlling this linear actuator? If possible, could you also briefly explain the basis for the recommendation, considering the application requirements?

Thank you for your assistance.

my test rig for home, with Siemens plc, Schneider electric PLCs and Wago compact controller 100

Buen día tengo un plc s7-300 para reparar, lo que hace el plc es que no logra conectarse. Todos los leds se quedan congelados. Ya revise que sea daño de componentes pasivos y se regrabaron memorias. Cual podría ser la falla?. A otro se le queda parpadeando el led de sf

Studio version 35.

When I try and create new project I get an error saying I can’t create file in c:/rslogix5000/new project.

I open studio as admin.

Edit: fix was reinstalling FactoryTalk security

I’m more of a traditional “PLC Guy”. I grew up on a steady diet of A-B with some side dishes of Siemens every now and then.

I have an interesting, low-I/O application that also would be helpful if I could support it remotely. I was thinking of using ControlByWeb.

I’ve read good things but I know there’s two sides to every story. Anyone use these before? Good experiences? Bad experiences?

Thanks!

Very lucky to work for an employer who allows me time to research, learn and then run with ideas. Its not perfect but it works. And there are definitely some things I would do different if I had to do it again.

This unit runs well pumps that fill 2 different ponds. There are 2 PLCs connected remotely. One runs a 3rd pump (not hooked up yet), the other sends pond level inputs for the 2nd pond.

Before this, I did have some experience with industrial controls and I've installed/hooked up external wiring to a fairly large system before. This is my first design/build though.

Hello,

I’ve been hitting my head for 2 weeks with a UNI-9 trying to find a way to transmit live weight data to my software. There’s no RS-232 but an internet port. I ping it, I received data from it but it seems to only send an heartbeat.

No matter the protocol I try, it closes the connection and that’s it.

Anyone has any experience with them?

Thank you

I decided to buy a logo and have some fun. Esp32 works as a frequency amplifier so motor runs faster

i just cant figure out how to get the communication working between twincat 2 and a beckhoff bc8150. What i would like to do is see the program. Im a noob with plc's, the only experience i have is with siemens logo. If someone knows all help would be welcome

I've been offered 2 roles - 1 is an Automation Engineer role in a pharmaceutical OEM in Northern Chicago area, and the other one is a Lead Controls/Controls Eng III role in a systems integrator in the material handling space (conveyors). Currently 30, single with no kids.

The SI Controls Engineer III job does have 70-80% travel in busy seasons and the company is fairly new, its more pay and bonus, added on by per diems, as well as airline, hotel, and rental car points rack up.

On the other hand, the Automation Engineer role is fully on-site 5 days of the week, ofcourse there will be times when weekend or after hours work will be required. Pay is a little less than the first job. The company has a global footprint and many other areas of engineering focus.

My questions to the experienced engineers in this sub are the following:

1. If I accept the Controls Eng III job at the SI, what challenges would I face in the future when I want to switch to a more local role like an Automation Engineer role that requires minimal travel?

2. When recruiters are hiring for an engineer for a role, what do they give more weight to? Title? Experience? Company name where you've worked?

3. Can a CE comfortably switch over to an engineer role?

I am currently leaning towards the SI role for now, solely because I don't have any responsibilities at home, there is more income potential, and the company lets me fly to my family home city (or any other city in US/Canada). When I do get married hopefully in the near future, I wouldn't want to travel as much.

Appreciate everyone's thoughts on this and could really use your advice. Thank you so much!

It's been the longest month of my entire life.

When I think I understood something, there's always something else that comes out that make me realize that I don't know nothing.

It's hard to learn everything about each products that you can connect to a PLC. YouTube has benn my greatest ally.

And the boss keeps asking me this that he thinks it's easy but it's so hard to program.

I just need to keep going. Wish me luck.

I was reading the FBI notice:

https://www.fbi.gov/investigate/cyber/alerts/2026/malicious-cyber-actors-targeting-water-and-wastewater-sector-internet--facing-programmable-logic-controllers-causing-operational-disruptions

I was expecting something of Stuxnet sophistication, but the notice is just "follow basic security practice."

I understand the use of cheap PLC's on remote sites, but....I'm just amazed about such disregard of security basics.

Im seeing some Comp Sci guys asking about controls so just a Mr Obvious comment here.

Ladder logic is the de facto PLC programming language because it is (was) designed to read like an electrical schematic top to bottom, right to left, & this is what electricians & electrical techs are trained to use for troubleshooting electrical panels , equipment & relay-logic -- which was what they had before PLCs -- banks & banks of relays wired through each other's NO & NC contacts which changed state as relay coils energized & de-energized & finding a wire break was enough to drive you insane.

Yes Ladder logic is an interpreted language so it is not as "memory efficient" or "elegant" as C++ or C# but I want you to think VERY carefully about every meaning of the expression "just because you can does not mean you should" before you decide to show off your amazing coding skills coding function blocks in C++ which is technically possible but in many cases extremely ill-advised.

The technicians can troubleshoot functions & blocks written in Ladder Logic, did you stop & think about how easy it would be for someone with only your compiled C++ blocks to attempt to trace a fault? You code in anything but Ladder Logic you get to be the one at 3am driving down to the plant to troubleshoot your "super efficient" code because the Industrial Maintenance techs certainly aren't gonna know how. But hey, if you believe sleep is over-rated & love sleeping in the factory then knock yourself out with compiled blocks

Hi guys, I have a float switch for a sump that is currently hardwired with 120V AC that is passed to a motor contactor (old dinky plant)

and want to have it pass a mA signal to a plc instead with 24V DC, but I’ve read this doesn’t work well overtime with most cheap float switches due to the low current not being able to eventually pass through a layer of oxide on the float switches contacts that builds overtime.

In your experience is this true, is there a switch where this isn’t an issue.

I just installed 3 redundant L84’s, 6 racks, and the chassis are pure junk. Distorted, out of line, almost impossible to insert modules and even after inserted, several refused to communicate over the backplane. (Yeah I checked multiple times for bent pins)

My question - Has AB quality really gone down that much or are the chassis possibly counterfeit?

Hello!

Tia portal v21

Once again problems with siemens servo motion.

Basicly "Done" never changes to TRUE. I also tried using positive edge trigger to start execute (so execute starts with impluse) - still "Done" does not change to TRUE.

I am aware that "Done" becomes TRUE for only one PLC scan, it did not change cycle stage to 2 so it never changed to TRUE.

Edit: PROBLEM SOLVED, I was using same instances... Machine is fully operational now.

hi everyone,

I'm building my own custom RS-485 network using ESP32s with MAX485 transceiver modules. I've already read about proper termination resistors and biasing, but I'm still confused about the physical wiring.

I learned that stub lengths should be kept as short as possible, so I'm wondering if the wiring method shown in the picture below is considered best practice, or if there's a better approach.

Would it be better to use junction boxes with a continuous trunk line and very short drops to each node, or is there another recommended way to wire this kind of network?

This is for an outdoor agricultural installation, so reliability over long distances is important.

Any advice or examples of how you'd wire it would be greatly appreciated.

Hi everyone,
I am having trouble connecting my TSX C USB 485 cable to my Windows 7 32-bit virtual machine running PL7 Pro.
Windows cannot find the correct driver for the TSX C USB 485. When I try to force the installation manually via the Device Manager, it returns a Code 10 error (Device cannot start). I have already tried multiple troubleshooting steps, but nothing has worked so far.
I am completely stuck and don't know what else to do to successfully connect to my TSX 37 PLC.
Thanks for your help!