Software for PLC Diagnostics, Analysis and Backup
Industrial software helps identify the cause of a fault faster, record the actual sequence of events and protect programs for PLCs, robots, HMIs and other production equipment against loss. The range includes auto.spy diagnostic software for long-term recording and retrospective data analysis, as well as PLC Auto Backup for automated backups, version management and rapid recovery of production technologies.
Do you need to investigate sporadic faults or automatically protect equipment programs?
We will discuss the types of PLCs and other equipment, the required recording method, number of signals, backup scope, version management, data recovery and cybersecurity requirements.
More about diagnostics, analysis and automated equipment backups
Two different tasks: finding the cause of a problem and protecting the correct program version
When production equipment fails, seeing only the current PLC status is often not enough. The technician needs to determine retrospectively what happened before the machine stopped, in what order the signals changed, and whether the event was related to the operator or a mechanical process. At the same time, it is important to know where the latest working program version is stored, who changed it and how quickly the equipment can be restored.
Long-term recording makes it possible to analyse an event that occurs only occasionally and is no longer active when the technician arrives.
PLC states, process values, events and camera footage can be compared at the same point in time.
Regular backups reduce the risk that only an old or incomplete project version will be available after a fault.
Central storage and version history reduce the time spent searching for the correct files and restoring the equipment.
Choose a solution according to the task
Software for recording, visualising and retrospectively evaluating machine data. It helps identify the causes of faults, analyse fast and long-term processes, optimise the process and document the actual behaviour of the equipment.
View auto.spyA solution for regular automated backup of programs, configurations and documentation. It tracks changes, retains version history and enables rapid recovery of PLCs, robots, HMIs, drives, computers and other equipment.
View PLC Auto BackupQuick comparison
| Area | auto.spy | PLC Auto Backup |
|---|---|---|
| Primary purpose | Diagnostics and retrospective analysis of data trends | Automated backup and version management |
| Typical question | What exactly happened before the fault? | Where is the latest working version of the program? |
| Processed data | PLC variables, OPC data, video and measurements | Projects, configurations, disk images and documentation |
| History over time | Trends of values, states and events | Program versions and configuration changes |
| Main benefit | Faster identification of the fault cause | Faster and more reliable equipment recovery |
| Typical users | Maintenance teams, PLC programmers and service technicians | Maintenance, automation, IT/OT and cybersecurity teams |
auto.spy – where can data be recorded from?
The solution is based on the auto.spy analyzer module. Drivers are then selected according to the data source and required recording accuracy. Two options are available for SIMATIC S7 PLCs: regular sampling without modifying the PLC program and detailed recording synchronised with a single PLC cycle.
Recording selected variables with regular-sampling accuracy or accuracy down to one PLC cycle.
Diagnostics and detailed value recording are also available for older SIMATIC control systems.
Recording data from OPC servers and other equipment available through the OPC interface.
Adding camera footage or signals from the external LabJack U12 measuring device to the recorded data.
First select the basic auto.spy analyzer module. Then add drivers according to the data source and required recording accuracy. Detailed guidance is available in the advisor How to choose the correct combination of auto.spy licences.
PLC Auto Backup – what can be backed up automatically?
For example Siemens SIMATIC, Rockwell Automation, Schneider Electric and Beckhoff.
Robot-cell programs and configurations stored centrally and updated regularly.
Backups of other critical devices whose configurations are required to restore production technology.
Central storage of configurations, images, projects and operating documentation.
What are the benefits of automated backup?
- Regular backups without manual operator intervention.
- Central storage for programs, configurations and documentation.
- Change history and an overview of available versions.
- Detection of changes in programs and configurations.
- Rapid recovery of the latest working version.
- Reduced dependence on service laptops and individual employees.
- Support for internal audits and cybersecurity.
- Protection of know-how and reduced risk of prolonged downtime.
Typical situations addressed by the software
The event occurs once every few hours or days and cannot be captured reliably using standard online diagnostics.
You need to compare PLC signals, process values and camera footage retrospectively.
It is unclear which program version is current and actually matches the equipment in production.
Production must be restored quickly from a verified backup without a lengthy search for files.
What should be checked before selection?
- Which types of PLCs and other equipment you need to monitor.
- Whether you are addressing diagnostics, backup or both.
- How many signals and devices will be included in the project.
- How fast the process is that you need to record and analyse.
- Whether camera recording is also required.
- How often equipment should be backed up automatically.
- How long data and versions need to be retained.
- Who should have access to diagnostics and backups.
auto.spy - software for diagnostics of SIMATIC S7-300/-400/-1200/-1500 and S5 PLCs, OPC UA/DA data and camera recordings
from 713,90 EUR Incl. VAT
How to capture sporadic faults on Siemens S7 PLCs
Sporadic faults on Siemens SIMATIC S7 PLCs are difficult to find using standard online diagnostics. In this article, we show how auto.spy analyzer helps capture signals, events and video on a single timeline and trace the root cause of the problem afterwards.
Advisor
How to choose the right combination of auto.spy licences
Diagnostic software auto.spy is used to record and retrospectively analyze the behavior of a machine or technology. It is used for finding the causes of faults, long-term equipment monitoring, process optimization, commissioning, and documenting the actual course of events. The basis is always auto.spy analyzer. Separate drivers are then selected according to where you need to obtain data from – for example from a Siemens SIMATIC S7 PLC, an older SIMATIC S5 PLC, an OPC UA/DA server, an IP/USB camera, or an external LabJack U12 measuring device. The choice of licence therefore mainly depends on two questions: which data source you need to monitor and how precise the recording needs to be.
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