I'm trying to get a better understanding of relay failure issues in industrial controls and wanted to hear from people who actually deal with this stuff in the field.

Say you've got standard interface/electromechanical relays between a PLC and field loads like solenoid valves, contactor coils, brakes, etc., and you're seeing certain relays fail noticeably more often than the rest. I'm curious what you guys normally look at first.

Would you usually suspect the relay is just undersized for the actual load, inductive kickback/suppression issues, high inrush, excessive switching cycles, cabinet heat, or something else? Also, when you run into an application that just keeps eating mechanical relays, what do you normally replace them with? Better mechanical relay, SSR, interposing relay/contactors, different suppression, etc.?

Same question on the input side: have any of you dealt with long cable runs, VFD noise, leakage current, or induced voltage causing PLC inputs to trigger when they shouldn't? What ended up fixing it? Not looking for a specific brand recommendation necessarily. Mostly trying to understand what solutions people are actually using and which relay problems are common versus just bad system design.

Here’s one for all the wash down lads. This is for an ice cream specialty machine.

Hey all, I wanna learn how MQTT works. Has anyone used Codesys with MQTT? can you suggest me a way to learn it and understand? Thanks

A huge thank you to everyone who helped me!

I took your advice and put together a new design with a lighter theme and more breathing room. I removed information that doesn’t need to be visible all the time—I’ll move it into pop-ups and other screens.

Green indicates that an unwinder is running, while gray indicates that it isn’t running.

The main overview now focuses on the essentials and feels much less cluttered.

I have been posing this question to my coworkers, but none of them seem to know the answer, so im hoping on reddit to see if anyone can explain this to me.

I have been looking at some code (Studio 5000) that we have on some older equipment and I noticed something strange. There was a Reset for an AOI that was being that was being Latched in the main but never unlatched anywhere. Looking at the AOI the Reset is set up as an Input Parameter and is being unlatched within the AOI, and it works?

Its always been my understanding that Input Parameters are read only and the only way to manipulate a tag from within an AOI and have it change the top layer is to set it up as an InOut.

What am I missing? I would like to be able to use this to my advantage and clean up my AOIs. Could this possibly cause memory issues elsewhere? What is best practice for doing something like this reset situation?

Hi everyone,

I'm having a strange issue with a ProSoft MVI56E-61850C and I'm wondering if anyone has encountered something similar.

I'm using:

• SEL-2240 Axion with SEL-5023 RTAC software
• SEL-787 Protection IED
• ProSoft MVI56E-61850C
• Rockwell ControlLogix 5580

I have generated a SCD file from acSEL Architect software. This file contains both SEL-787 and SEL-2240 configuration. I noticed ProSoft SCD importation doesn't works properly when using different IED types, so I tested importing their CID file.

SEL-787 configuration works properly.

When importing SEL RTAC CID I noticed that the ProSoft Configuration Manager recognized it with 2 IEDs with same name. I checked the file in text editor and removed unused access points (There were 10 AP total). Now the ProSoft reads just 1 IED.

Following to creating the tag list, when trying to import some Logical Node or Report with GGIOs causes the software to crash.

I noticed it only worked with an Logical Node with lnType = "GGIO_4". For testing reasons I manipulated using my text editor all GGIO LN lnType to "GGIO_4" and then the software stopped crashing.

I work with power station automation in transmission, we don't usually integrate our station bus with PLCs.

I tested the CID with IED Explorer and it worked properly. I tested with Elipse Power and SAGE, in those both SCADA it worked properly.

I tried contacting ProSoft support, they said the problem was with the CID File.

I tried creating a new CID from zero and it did not work either.

I’m working on a college automation project using a FE7370WE-4G HMI programmed with FStudio.

The HMI is connected to the internet and stores historical data internally. I have successfully configured the date-range selection and data filtering on the HMI.

The workflow up to this point is working:

Select From Date → Select To Date → Filter historical data

The remaining problem is with the Generate Report and Send Email functionality.

The HMI already has an option to export the stored data to a USB drive, and I can successfully generate the data in CSV and PDF formats.

What I want to achieve is:

1. Select the From Date and To Date.
2. Filter the historical data according to that range. (Already working)
3. Press Generate Report to generate a report containing only the filtered data.
4. Press Send Email and have the generated CSV/PDF report sent directly from the HMI to a Gmail address.
5. The recipient should be able to receive and view the report on a phone or PC.

Current setup

• HMI: FE7370WE-4G
• Software: FStudio
• Internet: Yes
• Historical data: Stored internally in HMI
• Data volume: Potentially thousands of records
• Export formats: CSV / PDF
• USB export: Working
• External IoT/gateway: Not being used
• Email service: Gmail
• Date-range filtering: Successfully configured
• Main issue: Generating the filtered report and sending it via email

I’m specifically looking for a way to implement:

From Date + To Date → Filter Data → Generate CSV/PDF Report → Send Email from HMI

I have not been able to figure out how to make the Generate Report and Send Email functions work for the filtered historical data.

Has anyone worked with the FE7370WE-4G / FStudio and knows how these functions can be configured?

Can this be done using FStudio scripting, SMTP, macros, APIs, or any other built-in functionality of the HMI?

I would prefer a solution where the HMI itself sends the email, without requiring a PC, Raspberry Pi, or external gateway.

Any help would be greatly appreciated!

Hey everyone,

Sorry for not have a brief video about project.

Sorry for the long delay on this update! Things got hectic getting everything over the finish line, but the machine is officially commissioned, up, and running.

How it’s going:

Performance: The machine has been running smoothly with a solid increase in productivity and zero downtime since the July 30 handoff.

Control & I/O: The Siemens ET200SP setup paired with ODOT remote I/O is handling the high density of winder monitoring and sequencing without an issue. The HMI overview gives operators full visibility across all 168 winder stations at a glance (run status, cycle times, idle count, and diagnostics).

Cabinet cooling (yes, ignore the pedestal fan!): Before anyone roasts the floor fan—it’s just a temporary stopgap to keep airflow moving during initial post-handover runs. It will be replaced with dedicated 6-inch exhaust fans and filtered louvers to seal the enclosure properly against textile dust.

Huge thanks to everyone who chimed in on the original post. Going from legacy control wiring to a clean, modern PLC architecture on a machine of this size was quite the project, but seeing it run continuously makes the effort worth it.

Has anyone on here configured the SMC ITV1050-ILN2N4 IO-Link Regulator in Studio5000? I am using the Keyence NQ-MP8L IO-Link Master. I believe my main issue is setting up the correct place to send the data from the NQ_ISDU_Write AOI. Any guidance would be appreciated

Does anyone have any clue how to fix this, I’ve restarted my laptop like 20 times and still. Thanks in advance.

Hey all,

I have been in automation for about 3 ish years and I was wondering when do you typically consider yourself “senior” status. I love my job, but I always look around to see what is out there for opportunities and see A LOT of senior positions. I’ve lead projects and wrote whole production lines from scratch. What do you need to start applying for these jobs. I know I can just apply, but I personally don’t think I’m ready yet. And like I said I love my job so I am probably not going anywhere anytime soon. Just curious.

Saludos ingenieros, soy un estudiante de último semestre en ingeniería mecatronica con especialización en automatizacion, en este periodo según establece mi plan de estudios tengo que presentar mi tercer proyecto, el problema es que estoy en blanco, no se que hacer, mi universidad me exige un proyecto que sea mejorar algo existente con automatizacion o bien crear algo automatizado, mis antecedentes anteriores fueron una máquina de embalaje automatica y un bebedero automático, la verdad me gustaría mucho que fuera un proyecto que no sea a escala pero que sea fácil de mover de un lado a otro,

alguna idea qué me puedan dar?

Best regards

Hi all,

Just yesterday, I was laid off without notice because our executives decided the plant's control team was making too much money. I'm still trying to process this, but I'm determined to take steps to not be the first on the layoff list in my future jobs. How would you recommend me to enhance my skills and be an engineer in demand? A lot of my tasks in my last job would get delayed because of budget reasons, but I can program PLC, have an understanding of NPN sensors and know how to wire them into PLC's, have experience with OT/IT networking, Linux, and most of my HMI work has been with FactoryTalk and Ignition. But I still always feel like I'm falling behind my peers in other engineering disciplines, and as this experience has taught me, controls engineers are looked down upon by executives who have no idea what work we do.

Hello everyone,

We are currently facing a challenge with the IFM PLCs CR0232 and CRO032, which will no longer be available after the end of 2027.

We still have a number of machines in the field that are equipped with these controllers, and sooner or later some of them will require repairs or controller replacement. Therefore, we are looking for a sustainable migration strategy and a suitable alternative platform that we can support for the next 10-15 years.

Is anyone else currently dealing with the same issue? Have you already identified a replacement controller or migration path that works well for mobile machinery applications?

Thanks in advance!

Im using a

WEINVIEW mt6103ip

S7 200 smart st40

Using rs485 2 wire

Cable isn't the issue. If I disconnect plc. On the hmi I get an error of mo communication. Same if I try swapping data cables.

Configuration on easybuilder pro and step 7 micro win smart are correct. Set for said protocol.

Objects like lamps or switches linked to hmi memory shows up.

But anything linked to a tag. Be it V.M.VM. don't show up

I need any help I can get. Been stuck here for a week.

Hi everyone,

​I'm currently working on my graduation project, and I'm using a CAREL pCO5 controller for my system.

​As a student, I am trying to figure out the proper way to access or obtain the 1Tool programming software for academic/learning purposes. Does anyone have experience with this, or could you point me in the right direction on how to contact CAREL or a local distributor for student/educational support?

​Any advice would be greatly appreciated. Thank you!

Hi everybody, i don't know if you could help me, i have a screen printing press and the cpu started flashing the on light and the error light is on, we changed the cpu, the new one still does the same, then we changed the power supply but nothing changed, anybody knows what i should do? Thank you very much

Everyone always asks about getting into PLCs, but nobody talks about going the other way.

I'd like to get off the road and switch to more PC based programming. I know the pay ceiling is way higher.

Has anyone ever done this ? I am worried about a pay cut initially and also what a true "average" to above average SWE makes that's not at a FAANG or Alphabet or whatever.

I currently make $130k base, around $165k with normal OT as a SWE at an integrator. 40% travel.

How do you document your PLC programs?

Not talking about the electrixal wiring diagrams, but the code it self so that when you get back to it, you can quickly understand whats happening without staring for hours.

What's your different methods?

I have to admit, I was wrong multiple times on this sub. I have been writing a program in ST on a Codesys platform the past week, cause that's what my customer wanted. ST really is the superior programing language... I'm sorry for doubting all of you nerds, I have joined you in the autism. I need not explain myself, if you know, you know. I am prepared to be downvoted by the non-believers and uncultured.

Guys, I’ve always felt that many industrial HMIs look unnecessarily outdated. So, for my latest project, I tried taking a different approach.

The interface is designed for a corrugated cardboard production line with five unwinders. The operator can see the current and previous roll lengths, reset the history, monitor line speed and shift production, check the current order, and access alarms and diagnostics.

It’s still a work in progress, and I know that an industrial HMI should be functional and safe before it is beautiful. I’m trying to find a good balance between modern visual design and practical usability on the shop floor.

What do you think?

Not sure if this is the right place to ask, but I would appreciate some guidance.

I work at a factory that produces chewable products, and one of our main processes is still almost entirely manual. We have very little process visibility, most parameters were developed through trial and error, and small deviations can sometimes create quality issues that take a long time to understand.

My first goal is to improve monitoring and traceability. I would like to measure temperature and humidity at several points, log the data automatically, view it remotely in real time, and eventually build a dashboard to compare batches and understand how process conditions affect product quality.

The next step would be automation. Temperature, exhaust fans, and air intake are currently controlled manually, and some of the manually recorded data has proven unreliable. Ideally, I would like the process to follow predefined drying curves automatically, probably using PID control for temperature and sensor readings to manage ventilation.

We contacted several automation companies, but the quotes were higher than management is willing to pay. I am therefore considering implementing a more budget friendly version myself.

How would you approach a project like this?

Hi I'm trying to upload from a CompactLogix 1769-L33ER/A (FW 21.011, SN: 70969701) using RSLogix 5000 v21.00 and RSLinx Classic Ethernet/IP driver.
When I try to upload, it gets stuck at "Uploading Tags..." and then the upload window just disappears without any error message.

Controller shows "Minor Recoverable Fault" in RSLinx Device Properties.
Already tried:
Increased timeout in Ethernet/IP driver
Running RSLogix as Admin
Cleared cache

Any ideas if this is a known bug with v21.00 vs v21.011? Do I need v21.03 exactly?
Thanks,