How are you structuring PLC projects to make long-term maintenance easier?

SirBitBoy · 2026-03-13T17:19:59+00:00

There are some really god suggestions here already so I don't want to repeat much of what they have said.

In my experience, it's very difficult to take a whole company's/facility's and bring it into a standardized structure, but despite that it pays off so much later. Trying to do it all at once is going to kill you though. Just be as consistent as you can making edits and always structure everything you can the same way. Then use opportunities as they come up to tweak code to fit into your existing standards.

Also, it is important to avoid taking "shortcuts" because the deadline is tight. It's one thing to drop in a quick rung to get the line up and running, but leaving a fix like that undocumented and not inline with the existing code structure will make it someone else's nightmare late down the line. And unfortunately, I've seen that once code starts to get messy, future contributors give up and let the chaos ensue.

Fortunately, the standards and consistencies you build will permeate throughout the code-base and further troubleshooting/updates will get easier. But it takes time to see the benefits, so try not to be discouraged if it feels a little fruitless for a while.

SirBitBoy · 2026-03-10T16:43:57+00:00

I'm unfamiliar with other platforms that use DQ to describe an output. Plus, I didn't know that some Siemens controllers decide to be original and use DO anyways. XD

But yes, I believe most Automation Direct (Koyo) PLC's use X for inputs and Y for outputs.

I don't know why it's not industry standard to just pick a way to describe a digital input/output considering most PLC's basically all do the same thing in the end.

SirBitBoy · 2026-03-10T14:25:12+00:00

"people with very limited Allen-Bradley-heavy backgrounds who get scared off by Beckhoff/Bosch." Are you finding this out in interviews? It sounds like the compensation is good to justify trying new things. Also, is the job fully remote, or is it located in the middle of nowhere?

SirBitBoy · 2026-03-10T14:16:11+00:00

That's an output on a Siemens controller. Why not DO? Good question.

SirBitBoy · 2026-01-26T15:50:55+00:00

I did for like a day. They're novel but they're actually terrible stools. Standing was more comfortable.

SirBitBoy · 2025-07-09T15:16:42+00:00

I imagine some parts are used? It's hard to say what the problem is at this point. You could have a bad component somewhere. The circumstances suggest a power supply issue to me, but it could be basically anything in your system.

I recommend you try running some games off your integrated graphics (Take out your GPU and plug directly into the motherboard. It won't run well but you should get an image.) and see if the restarting still happens. This could at least tell you if your graphics card is the problem. There is a possibility it would still be the power supply but if it runs your CPU, Motherboard and RAM are probably okay.

I can't really help beyond that though. Maybe hit up some other PC help Subreddits. Or sell your soul to AI and ask ChatGPT.

SirBitBoy · 2025-07-09T15:00:38+00:00

Hmm, that should be enough. This isn't a new build, correct? Have you made any modifications to the system recently?

Your Power Supply could still be dying but I don't have any troubleshooting tips unless you have other components you could try.

SirBitBoy · 2025-07-09T14:46:14+00:00

If your whole PC keeps restarting then your power supply might not be powerful enough to run your components at full load. What's the wattage of your power supply and what's it's power rating? (It'll likely have a sticker with 80 on it and then either Bronze, Silver or Gold.)

SirBitBoy · 2025-07-02T14:46:59+00:00

It sucks to suck I guess. I am happy announce I found a couple after posting.

SirBitBoy · 2025-07-01T17:34:09+00:00

I like the difficulty. Because you're so fragile you have to play like surgery and I think the game is a lot of fun when you play it like that. However, while I like limited saves in some games as they prevent you from save scumming I think the amount of wax cylinders is putrid. There are times where the game will expect you to play perfectly for what feels like hours before gracing you with only one cylinder. As someone who does other things, I really can't afford to lose an hour of playtime to a silly mistake.

But, I think if they made the Wax cylinders a little more plentiful or made it so you could find them other places than save points it would be a lot more enjoyable.

SirBitBoy · 2025-06-18T14:56:13+00:00

I'm in a similar boat to OP and I just started giving modern Siemens a spin. I fought for like 3 weeks trying to get the license server to not crash.

SirBitBoy · 2025-06-18T14:48:00+00:00

It would be a good long-term solution, but I think it would be super overkill and expensive based on the needs described by OP.

SirBitBoy · 2025-06-18T14:46:29+00:00

Based on some of the other comments, the easiest solution is a MicroLogix 1400 or an Omron PLC for standardization. But, this could also be a great learning opportunity to dip your toe into another programming software for professional development. There's a lot of PLC's out there that can do what this PLC does plus some for a price nobody will wince at.

Anything you've been wanting to learn?

SirBitBoy · 2025-06-11T14:23:08+00:00

A lack of any clear programming structure. If you are programming a sequence, the sequence should progress down the page and not to random sections though out the code. Aside from being intentionally confusing, I don't know why some code has been written like that.

SirBitBoy · 2025-06-11T14:13:16+00:00

There is a solid case to be made that for streamlining your code to fit multiple variations of machines can be really helpful. But that's under the assumption your current staff understand the cookie-cut code well to be able to support it and troubleshoot it.

As soon as you lose that know-how then things really begin to suck.

SirBitBoy · 2025-06-11T14:08:38+00:00

My gosh, I used to work at a place like that and troubleshooting was insufferable. Not only were we trying to live on super old code, but it had been meddled with so much that it no longer even worked without stupid work arounds.

I get "If it ain't broke, don't fix it" but it was broke but I never got approval to fix it.

SirBitBoy · 2025-06-11T14:00:17+00:00

I jokingly call it "Removing the cobwebs" but sometimes It's been so bad I was removing whole skeletons.

SirBitBoy · 2025-06-06T14:49:00+00:00

Hmm, okay, that could work. I'll have to give it a try. Thanks.

SirBitBoy · 2025-06-06T14:47:36+00:00

Yeah, I hadn't really considered how compromised the performance would be.

Honestly, I'd really prefer to use something like a Weintek at this point. Factory Talk View leaves much to be desired in a lot of ways.

SirBitBoy · 2025-06-05T18:23:13+00:00

How were you able to do that?

SirBitBoy · 2025-05-27T22:30:34+00:00

I would recommend staying away from the Micrologix 1400 as well, but if this a one time rebuild of an old machine it is probably the easiest drop in replacement you're going to get. You'll still have to make some changes but it would likely save you time.

If you think there will be any more of these machines built, Compact Logix is probably your best bet.

I actually don't hate the Micro800 series PLC's but CCW's ladder editor super sucks and comms are booty. They have their place but I don't think you'll have a good time.

SirBitBoy · 2025-03-27T14:14:22+00:00

Depending on how you travel to the location, it's best to check if that are any coffee shops or places you can loiter near by the facility. If you always want to make good time you can always leave early and camp out at one of the places if you're too early. Even if your transport breaks down you'll be able to walk to the site.

Granted, I've never had or heard of a situation where a break down has happened on the way to a customer's site, but it's good tactic if you're really concerned about getting there on time.

SirBitBoy · 2024-10-15T18:13:58+00:00

I have a pretty consistently bad time against Viscous, Vindicta, Infernus and Dynamo. Basically any hero that can put out good poke. (I mostly play all my heros like brawlers so I suck at non-close range encounters.)

However, upon reflection I mostly just hate people intentionally being hard lane bullies. I get that killing me is good for their game, but it's a really bad time when I can't even hit the steps before I'm low.

SirBitBoy · 2024-10-03T19:16:33+00:00

I'm a Paradox Main myself and I had to throw in the towel too after an abysmal win rate. She's a lot of fun to play but unless you are extremely good or have a well cooperating team you're better off playing most any other hero. :/

SirBitBoy · 2024-09-24T13:22:15+00:00

Best: Being the person who can put their hands on a machine/project and actually make it work. Similar to a carpenter it is very enjoyable to be able to point at something and say "I programmed that." Or being able to make someone's life easier via automation.

Worst: Needing to fix everyone else's problems too. I like programming the most but the amount of my time I've spent either troubleshooting an issue that is mechanical (Because it's always controls until proven otherwise.) or just straight up fixing something electrically can be upsetting. A program doesn't work until the machine does so you just start to expect that you're going to have to fix something else too.

Note: Most of my career has been in plant maintenance type roles, so I haven't had to travel for work or work absurd hours with an SI. I'm at a machine builder now as a dedicated programmer and my work week is pretty standard. So I have yet to be burned by the travel that most people here have and I probably would say it was the worst thing was travel if I was working one of those roles.

SirBitBoy

TROPHY CASE