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question

As a junior engineer inheriting a 15-year-old Siemens S7-300 system with no documentation, what's your systematic approach to reverse-engineering the PLC logic without causing production downtime?

answer

First, create a complete backup of the existing program using Siemens TIA Portal or Step 7 software before making any changes. Document all physical I/O connections and wiring during scheduled maintenance windows. Analyze the program structure starting with organization blocks and use cross-referencing tools to trace logic flow without modifying the running system.

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