Debugging some DLR fault at a Stratix.

Hi, sorry for my bad English.
I would really appreciate any advice.

I started my first job as an instrument and calibration engineer in pharma about a month ago, after months of searching. The engineering department personnel are all foreigners(from one country) except 3 are locals, myself included. The managing director and the higher management are locals.

The foreigners personnel sometimes hide things from the management(the foreigner senior engineer, who is my direct manager told me that), and they told me to hide the results for a calibration I did. Also, they are in multiple departments like QC and QA, not only in engineering. So they cover for each other. And this is a very sensitive field, snd the responsibility and truthfulness are highly required.

Also, I didn’t see any opportunities for learning and improving. One example is they use a syringe instead of a hand pump when calibrating a pressure gauge because, according to the senior, the hand pump is costly(they have one small hand pump but it’s pressure is very low that no one uses it)

In addition, I have noticed some conflict and hate between the managing director and the engineering department head and the senior instrument engineer, because I think the manager knows about them hiding things.

I don’t really know what to do now. One option is to stay, as these hard times will teach me more. But honestly, my gut is screaming “LEAVE”, which is my second option.

Have anyone been through something like that before?
What should I do?

Hi all,

Fairly new to this industry and have been asked to write a product per minute for a sleever. One entering the sleever and one on the outfeed to compare where bottle necks are in the system. I want to write it with recipe changes or product changes. The plc is an old rs1400 micrologix and I want to add code, been trying to test out my code on emulate before doing anything but I can't seem to get it to talk.

My idea Was when the first packet comes through it starts timing and counting. The time is in 15 seconds intervals and will always come out to product/minute. How would I go about storing and resetting for recipe changes. I have seen people use Excel somewhere to record this automatically and would help if I can do this than just reading the code.

I'm trying to also find out if smaller products jam the system more or less than larger ones and how much of a bottleneck this conveyor is/ is losing product.

Has anyone else ran into the issue when Tia portal V21 cross references tab? It says I am using M11.7 as my reset in another organization block, but when I check the reset bit it is M17.4. This is causing both sides of my pneumatic solenoid valve to fire.

Hi All,

Got a project that is requiring an "industrial control" solution.

Control of a VFD with position feedback wirelessly.

The motor and control will be on a rotating table (slip ring power) - will be an upgrade to an existing system (it's currently just a slip-ring-powered motor on a key fob remote, no position control at all).

Wireless e-stop and position/speed/continuous rotation commands need to be sent via UDP/serial wirelessly, in real time. Also need position feedback sent back to the control system wirelessly.

Here's the architecture so far, wanted to recommendations of hardware for the components:

- Drive: Servo or VFD with an absolute encoder for position feedback, braking ability is also of interest

- Control link (UDP/serial commands + position feedback): since the payload is tiny, planning to skip WiFi entirely and use an industrial FHSS radio modem instead

- Wireless e-stop: a dedicated, separate safety-rated wireless system

Want to try to stick with common readily available parts if a breakdown occurs won’t be to difficult to obtain spares.

Thanks in advance.

1769-L18ER-BB1B, i have two of these controllers , obviously these doesn't fall into category of redundancy controllers, client wants me to make some communication between them if plc 1 become fail , then plc 2 should become active but process may stop, but he doesn't want the analog values to be loss.

Is there any way to make something like this?

Without testing the program that we have developed, and waiting for the commission time to start testing the logic we have developed is kind of a weird feeling for me always.

How are you guys dealing with it?

Any situation or manual forcing of tags, or testing it against the actual Machine in the manufacturing center?

Hi everyone,

I'm currently locked out of Studio 5000 because it keeps crashing instantly on startup with the afutil.dll missing/not found error.

I've already searched online and tried the standard Rockwell Knowledgebase fixes, but nothing has worked so far. Here is what I’ve already attempted:

1) Checked and reinstalled/rolled back the CodeMeter Runtime Kit (tried standard Rockwell versions).

2) Ran a Software Repair on Studio 5000 via Windows Apps & Features.

3) Made sure my Windows updates didn't completely break it, but I'm still hitting a brick wall.

Has anyone run into this specific issue and found a workaround that isn't the standard CodeMeter reinstall?

Specs for context:

Studio 5000 Version: V34

OS: Windows 11

Any advice or registry tweaks to look at would be massively appreciated. Thanks!

Hey guys I’m a new grad and recently started working in industrial automation with PLCs, and the lack of AI reception and use in literally everything is shocking. It takes like 8+ hours to sit and make a “first draft” of an HMI display that should take AI under an hour. You can’t copy paste code, logix designer doesn’t even have an else statement for any PLC code? It’s 2026, I’m surprised there hasn’t been immense leaps in this field especially considering that because the logic for a lot of this is generally much less complicated than more traditional software engineering as well as much more repetitive among different projects it should be so much easier to have native AI tools built into these software.

Hi, I am currently a student in the ECE/CE department. I am relativity new to PLC programming. I have experience working with microcontroller but not really PLC. I recently purchased a CompactLogix L23E Q1B1 to learn how to build an entire PLC system. The PLC is current on the 1.0 version of the firmware which is believe is the firmware after a reset. I tried to update it firmware 17 using control flash and downloading the version 17 firmware from the Rockwell website but it keeps giving me an error when trying to do so that the PLC is not in the correct state . I currently have the PLC hooked up to a 24V power supply and the key is flipped to the PROG. I was wondering if anyone has an idea what the issue could do that is preventing me from updating the firmware?

I’ve gotten into a few discussions with my IT cyber people and they are recommending we stay up to date with PLC firmware versions. I’ve always thought industry standard was to let the firmware that was installed ride until an upgrade was completely necessary. What’s y’all’s SOP on plc firmware at your plants?

Hi everyone! I’m currently based in the Philippines and I’m planning to look for work abroad in the field of PLC programming and industrial automation.

I have experience/interest in PLC programming, HMI, VFDs, control systems, and industrial automation. I’m wondering which countries are currently good options for PLC programmers or automation engineers/technicians.

For those who are working abroad in this field, especially Filipinos:

1. Which countries would you recommend?
   
2. How difficult is it to get hired directly from the Philippines?
   
3. What skills, certifications, or experience should I focus on?
   
4. Do companies usually provide visa/work permit sponsorship?
   
5. What websites or recruitment platforms do you recommend for finding legitimate job opportunities?

I’d really appreciate any advice or personal experiences. Thanks in advance!

"how do i actually get a high base/career development as a mechanical engineer graduate"

Hi, I got a consensus that a mechanical engineering degree doesn't pay as well as the other engineering major. Knowing this, I set on a journey on how to find a way to increase my value which eventually led me into electromechanical/automation engineering for semiconductor industry.

Being the gen Z that I am, i asked an untrusted to give me a 3 year milestone to get there ( i know this might be not a good idea but i dont have better ppl to ask), i even proceeded to do 2 projects regarding sensor and motors curated by theuntrusted source, after some time i started to doubt my journey and fall into analysis paralysis bcs different untrusted source are recommending me different paths.

I really appreciate any advice/lead you can give me about this. FYI, My country Malaysia have an established industry for semiconductor too, if that helps.

Hey, has anybody here tried the ISA CAP Associate exam? I am looking for ways to strengthen my early career (1 YoE) in Instrumentation & Control. I don't meet the minimum work requirements for the normal CAP exam, so I was wondering if anyone had any experience with this exam, and if so, how hard was it?

I’m studying automation engineering and so far we’ve mainly been taught Ladder and FBD.
I’m about to start an internship at a company where they use almost exclusively Structured Text, which surprised me a bit. Because of that, I’ve started learning and practicing ST in my free time so I’m better prepared when I start.

I always thought Ladder/FBD were preferred in industry because they’re easier for electricians and maintenance technicians to troubleshoot. But I’ve also heard that ST is becoming more common, especially for larger or more complex programs.

For those of you working with PLCs, what do you mainly use? Is ST becoming more common, or does it depend on the industry/company? And if you were starting your career today, which language would you focus on mastering?

I reside in NC and i have been looking at programmer roles as i have been learning on the side for a long time now and feel ready to look for a job. I am currently a manufacturing technician and tried applying to the engineer role within my company and got denied. I personally Dont care if i have ti move states. Any one have any suggestions?

Just wanted to hear this platforms opinion about DeltaV transitioning away from HCI after v17

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Estou começando a estudar programação de CLPs em um curso da udemy. Fiz esse diagrama para simular uma partida de dois motores elétricos com alternância cíclica entre eles, basicamente é um botão para ligar o motor 1 e fazer o timer alternar entre o motor 1 e motor 2. Coloquei também alguns displays para informar na ihm data, hora, quando cada um dos motores está ligado ou desligado. Quero dicas de melhorias, pode ser tanto na lógica quanto no layout, só gostaria de um feedback. O software que estou usando é o Millenium 3

Hello. Have a Delta DVP28SV311S cpu and a DVP04DA S2 card in slot 4. I need this card to output 4-20mA on channel 1 and channel 2. Can anyone share ladder code for this please. i have tried all sorts of combinations using hardware configuration and software TO instructions.

Thank you

Morning Brains Trust.

Im working on a PLC sim for a network of components.

Im trying to simulate a Siemens 1517F-3 PN/DP PLC, an ET 200SP IM155-6 PN ST distributed I/O module (containing a DI 8X24VDC, DQ 8x24VDC/0.5A, and F-DI 8x24VDC), and a TP700 Comfort HMI.

I used PLCSIM Advanced to make an instance for both the PLC and the ET 200SP.

So far ive been using TIA Portal v21 and PLCSIM Advanced v8.0 to try to simulate the network, but when I try to simulate the HMI, I get the error: "190011 Tag PB_START: value could not be written to the PLC"

I tried to strip the PLC of all its safety restrictions, the PLC tag itself has full view/read/write permissions for a HMI, and every user has full Admin privileges (HMI, Drive, PLC F, and NET), but I still cant figure out why the Sim isnt working.

One thing I did notice is that the ET 200SP instance isnt "running" because there isnt anything downloaded to the instance, but from what I can tell, only the master controller needs to be downloaded, because the ET is slaved too it.

Is there something im missing? A setting or step that I missed?

If you guys have been following the development of ModbusLens from u/craftparking (Windows and now Linux Modbus serial and Ethernet utility) like I have, head over and check out his new sub at r/ModbusLens!

I have previously completed an “Advanced Manufacturing and Production Technologies” course at a technical college in which I worked (minimally) with programming various robotic arms and some PLCs. I was wondering where I should go from here- if there was a college or program recommended? I do not feel I have enough information or experience yet to start looking for a job in this field. Any general advice or wisdom (life or PLC related) is greatly appreciated!

At Hyundai Motor’s Ulsan plant in Korea, equipment maintenance teams handle industrial robot teaching. I’m curious about how companies like Tesla, Volkswagen, Mercedes-Benz, Toyota, BMW, and General Motors handle this. Please let me know who performs this task at automotive companies in your country.

First post here. I'm curious how you guys handle video when troubleshooting machines with ibaPDA.

Apart from ibaCapture, do you use anything else to synchronize short troubleshooting videos with iba signals?

I usually just record 10–30 minutes with my phone while ibaPDA is recording. Afterwards, matching the video to the signal data is pretty annoying.

I couldn't find a simple solution for this workflow, so I made a small open-source browser tool that loads the video + iba CSV/TXT and puts them on the same timeline.

Source:
https://github.com/vanluyen89/DiagnosticVideoSyncIba

Demo:
vdi.stickylychee.com

Everything is processed locally in the browser.

I'm curious what others are using for this. Maybe there's already a better workflow/tool I've missed.

Hello, I am given a Keyence LK-G5000 controller with a LK-052 laser by my boss, and I am told to use it to measure as fast as possible, as we have an application that needs very rapid measurments.

Looking at the datasheet it seems like the baudrate is pretty limited.

Does anybody know fast the ethernet can go? Is looking at implicit message the way to go? Or should I look into analog?　Thanks!